Chevrolet - Colorado 2wd - Workshop Manual - 2009 - 2009

Factory Workshop Manual Make Chevrolet Model Colorado 2wd Engine and year V8-5.3L (2009) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views Central Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Below the I/P Components - 1 of 2 1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 14 Central Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 15 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 24 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 25 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 26 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 32 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 38 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 43 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 44 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 45 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 50 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 55 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 61 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 66 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 71 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 77 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 78 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 79 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 84 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 89 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 90 Communications Control Module: Diagrams Component Connector End Views Vehicle Communications Interface Module (VCIM) X1 Vehicle Communications Interface Module (VCIM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 91 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 92 Communications Control Module: Service and Repair Communication Interface Module Replacement Removal Procedure Note: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Ensure the ignition switch is in the OFF position. 2. Remove the service panel located on the right side of the instrument panel (I/P). 3. Disconnect the VCIM electrical connectors as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 93 4. Remove the screw retaining the VCIM to the bracket. 5. Release the tab (1) on the bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 94 6. Remove the VCIM from the bracket. 7. Remove the VCIM from the vehicle. Installation Procedure 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 95 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VCIM to the bracket ensuring the retaining tab (1) is fully seated. Tighten the screw fully driven , seated and not stripped. 3. Connect the VCIM electrical connectors as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 96 4. Install the service panel. Note: After replacing the VCIM, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 5. Reconfigure the OnStar(R) system. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 6. When replacing the communication interface module be sure to transfer Bluetooth Antenna, if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 105 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 111 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 125 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 131 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Global Positioning System Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 140 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Global Positioning System Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 146 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Navigation Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 155 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Navigation Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 161 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 170 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 171 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 172 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 178 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 179 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 180 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Under the Passenger Seat Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 185 1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger (KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1) 7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 186 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 192 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 193 Electronic Brake Control Module: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 194 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 195 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 196 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 197 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 198 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition switch to the OFF position. 2. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair). 3. Remove the electronic brake control module (EBCM) bolts (1). Discard the bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 199 4. Carefully separate the EBCM (1) from the BPMV. 5. Remove the 12 EBCM to BPMV seals (2). Installation Procedure 1. Carefully install the EBCM (1) and the 12 seals (2) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Do not reuse the EBCM bolts. Install new bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 200 2. Install new EBCM bolts (1) and tighten to 2 Nm (18 lb in). 3. Install the EBCM/BPMV assembly to the vehicle. Refer to Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 205 Compressor Clutch Relay: Service and Repair Compressor Relay Replacement Removal Procedure 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). Installation Procedure 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations Low Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Service and Repair Trailer Lighting Module: Service and Repair Trailer Lamp Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 239 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 240 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views Body Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 258 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 259 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 260 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 261 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 262 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 263 Body Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Right Kick Panel Components 1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body Control Module (BCM) X2 6 - Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 264 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 265 Body Control Module (BCM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 266 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 267 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 268 Body Control Module: Service and Repair Body Control Module Replacement Removal Procedure Important: * The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). * Always disconnect the black body wiring harness connector FIRST and the gray instrument panel (I/P) wiring harness connector LAST. * Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness LAST. * Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Disconnect the body wiring harness electrical connector (1) from the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 269 4. Disconnect the I/P wiring harness electrical connector (1) from the BCM. 5. Release the fastener retaining the body wiring harness electrical connector to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 270 6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle. Installation Procedure 1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3. Install the 2 fasteners retaining the BCM to the hinge pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 271 4. Install the fastener retaining the body wiring harness electrical connector to the BCM. 5. Connect the body wiring harness electrical connector (1) to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 272 6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 277 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 278 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 279 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 280 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 281 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 282 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 283 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 284 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 285 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views Engine Control Module: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 288 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 289 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 290 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 291 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Rear of the Engine Compartment Components - 1 of 2 1 - Engine Control Module (ECM) 2 - Front Plenum Panel Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 292 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 293 Engine Control Module (ECM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 294 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 295 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 296 Engine Control Module (ECM) X3 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 297 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 298 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 299 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 300 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should normally consist of either replacement of the ECM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). 3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from the ECM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 301 5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing the ECM (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 302 1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket. Ensure that the tabs (2) secure the ECM (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral CPA retainers on the engine wiring harness electrical connectors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 303 4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed, the ECM must be programmed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 307 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 308 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 309 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (K18) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 318 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 325 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 326 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Relays and Modules - Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 327 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 332 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 333 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 334 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 335 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 336 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 337 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 338 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). 3. Cut the carpet along the "I" cut pattern over the inflatable restraint sensing and diagnostic module (SDM). 4. Fold the carpet back to expose the SDM. 5. Disconnect the electrical connector (2) from the SDM (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 339 6. Remove the nuts (2) retaining the SDM (1) to the floor studs (3). 7. Remove the SDM from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the SDM (1) to the floor studs (3) with 3 nuts (2). Tighten the SDM nuts to 9 Nm (79 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 340 2. Connect the electrical connector (2) to the SDM (1). 3. Fold the carpet back down over the SDM. 4. Install the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). Note: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 6. Program the SDM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Relay > Component Information > Locations Air Bag Relay: Locations Component Connector End Views Relay Inflatable Restraint Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Battery Control Module > Component Information > Diagrams Battery Control Module: Diagrams Component Connector End Views Generator Battery Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement Charging System Control Module: Service and Repair Generator Battery Control Module Replacement Generator Battery Control Module Replacement (V8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 352 Charging System Control Module: Service and Repair Generator Battery Control Module Replacement (4 and 5 Cylinder) Generator Battery Control Module Replacement (4 and 5 Cylinder) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 371 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 372 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views Power Door Lock Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 388 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 389 Power Door Lock Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 390 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Right Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 391 1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door Harness) Left Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 392 1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 393 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock/Window Switch - Driver X1 (A31/AU3) Door Lock/Window Switch - Driver X2 (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 394 Door Lock/Window Switch - Passenger (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 395 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door Door Lock Switch Replacement - Driver Door Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel opening. 4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate. 7. If replacing only the switch plate, retain the switches for transfer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 398 Installation Procedure 1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the switches (2, 5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the switch plate assembly to the door trim panel with the 2 screws. Tighten the front door switch plate screws to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 399 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front Door Lock Switch Replacement - Passenger Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Door Component Views Power Mirror Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Door Component Views > Page 404 Power Mirror Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 405 Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DE6) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Passenger Seat Components - 2 of 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 409 1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 410 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver X1 (AG1) Seat Adjuster Switch - Driver X2 (AG1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 411 Seat Adjuster Switch - Passenger (AG2) Seat Lumbar Adjuster Switch - Driver (AG1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 412 Seat Lumbar Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Removal Procedure 1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Body and Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 3. Remove the buttons from the switch (2). 4. Release the tabs (1) that retain the seat switch (2) to the seat bezel. 5. Disconnect the power seat switch harness (1) from the seat harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 415 6. Remove the power seat switch from the seat bezel. Installation Procedure 1. Connect the power seat switch harness (1) to the seat harness. 2. Install the power seat switch (2) to the seat bezel. Verify that the retaining tabs (1) are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Body and Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 416 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Removal Procedure 1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Body and Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 3. Remove the buttons from the switch (3). 4. Release the tabs (4) that retain the seat switch (3) to the seat bezel. 5. Disconnect the lumbar switch harness (1) from the seat harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 417 6. Remove the lumbar switch from the seat bezel. Installation Procedure 1. Connect the lumbar switch harness (1) to the seat harness. 2. Install the lumbar switch (3) to the seat bezel. Verify that the retaining tabs (4) are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Body and Frame/Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Front of the Headliner Components (CF5) 1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 421 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 422 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair Acceleration/Deceleration Sensor: Service and Repair Longitudinal Accelerometer Replacement Removal Procedure 1. Remove the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). 2. Access the sensor through service slit provided in the carpet. 3. Disconnect the longitudinal accelerometer electrical connector. 4. Remove the nuts (1) from the longitudinal accelerometer. 5. Remove the longitudinal accelerometer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 427 1. Install the longitudinal accelerometer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the longitudinal accelerometer nuts (1) and tighten to 9 Nm (80 lb in). 3. Connect the longitudinal accelerometer electrical connector. 4. Install the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 432 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 433 Brake Fluid Level Sensor/Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 434 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 435 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 436 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 437 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Removal Procedure 1. Remove the electrical connector from the sensor. 2. Using a pair of needle nose pliers bend on a 90 degree angle, release the retaining clip. 3. Remove the sensor from the master cylinder. Installation Procedure 1. Install the fluid sensor in the master cylinder. Make sure that the sensor is fully seated. 2. Install the electrical connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 441 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 442 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 443 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 444 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 445 Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (2WD) (JL4) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views Parking Brake Release Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 450 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 451 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 452 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 453 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 454 Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Below the I/P Components - 2 of 2 1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowl Side Inner Panel Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 455 Parking Brake Release Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Page 459 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in). 3. Install the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Page 460 4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams Traction Control Switch: Diagrams Component Connector End Views Traction Control Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 464 Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Wheel Speed Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 469 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 470 Wheel Speed Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 471 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 472 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 473 Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Front Wheel Knuckle Components 1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Left Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 474 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front Wheel Speed Sensor (WSS) - Right Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 475 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning ). 1. Within the engine compartment, disconnect the wheel speed sensor electrical connector (1). 2. Release the wheel speed sensor harness connector from the wheelhouse. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 5. Release the wheel speed sensor harness clips (1) from the suspension upper control arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 478 6. Release the wheel speed sensor harness grommet (1) from the mounting bracket. 7. Remove the wheel speed sensor harness bracket bolt (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 479 8. Thoroughly clean the wheel speed sensor mounting area of the steering knuckle of any dirt and debris. 9. Remove the wheel speed sensor bolt (1). Note: Do not pry or lever against the wheel speed sensor to remove. 10. Carefully remove the wheel speed sensor from the suspension knuckle by pulling straight upward. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 480 1. Install the wheel speed sensor to the suspension knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 8 Nm (71 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 481 3. Install the wheel speed sensor harness bracket bolt (1) and tighten to 9 Nm (80 lb in). 4. Install the wheel speed sensor harness grommet (1) to the mounting bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 482 5. Install the wheel speed sensor harness clips (1) to the suspension upper control arm. 6. Install the wheel speed sensor harness connector to the wheelhouse. 7. Connect the wheel speed sensor electrical connector (1). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 483 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning ). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the wheel speed sensor bolts (1). 3. Remove the wheel speed sensor (1) from the drum brake backing plate by carefully pulling straight outward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 484 4. Release the wheel speed sensor harness retainers (1) on the rear park brake cable. Release the harness from the retainers. 5. Disconnect the wheel speed sensor electrical connector (1). 6. Release the electrical connector and harness retainer (2) from the frame. 7. Remove the wheel speed sensor assembly. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 485 1. Position the wheel speed sensor assembly to the vehicle. 2. Connect the wheel speed sensor electrical connector (1). 3. Install the electrical connector and harness retainer (2) to the frame. 4. Position the wheel speed sensor harness to the retainers (1) on the rear park brake cable. 5. Fasten the wheel speed sensor harness retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 486 6. Install the wheel speed sensor (1) to the drum brake backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the wheel speed sensor bolts (1) and tighten to 17 Nm (13 lb ft). 8. Lower the vehicle. 9. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 490 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 491 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 492 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 493 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 494 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (2WD) (JL4) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 495 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 501 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 502 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 3. Remove the ECT sensor (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 503 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Install the ECT sensor (1). Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 504 System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 509 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 510 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 511 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 512 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments Clutch Switch: Adjustments Clutch Pedal Cruise Control Release Switch Adjustment 1. Disconnect the clutch release switch electrical connector (2). 2. Rotate the clutch release switch (4) counterclockwise, allowing the retainer (5) to release. 3. Pull the clutch pedal to full stop. 4. While holding the clutch pedal at full stop, push the switch (4) inward fully until the switch body contacts the clutch pedal arm. At this point the plunger in the switch (4) should be pushed in. 5. Rotate the switch (4) clockwise until a "click" is heard. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 516 6. Connect the clutch release switch electrical connector (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 517 Clutch Switch: Service and Repair Clutch Pedal Cruise Control Release Switch Replacement Removal Procedure 1. Disconnect the clutch release switch electrical connector (2). 2. Complete the following in order to remove the clutch release switch (4) from the clutch pedal bracket (1): 1. Rotate the switch (4) counterclockwise. 2. Pull the switch (4) from the retainer (5). 3. Push the locking tabs inward to release the retainer (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 518 1. Slide only the clutch release switch retainer (5) into the clutch pedal bracket (1), until the locking tabs are fully engaged. 2. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control Release Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Component Connector End Views Cruise Control Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 522 Cruise Control Switch: Adjustments Cruise Release Switch Adjustment 1. Disconnect the cruise control release switch electrical connector (1). 2. Rotate the cruise release switch counterclockwise, allowing the retainer to release. 3. Pull the brake pedal rearward to full stop. 4. While holding the brake pedal in position rearward, push the switch inward fully until the switch body contacts the brake pedal arm. At this point the plunger in the switch should be pushed in. 5. Rotate the switch clockwise until a "click" is heard. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 523 6. Connect the cruise control release switch electrical connector (1). 7. The switch is properly adjusted when there is 7 mm (0.28 in) clearance between the end of the barrel and the striker plate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 524 Cruise Control Switch: Service and Repair Cruise Control Release Switch Replacement Removal Procedure 1. Disconnect the electrical connector from the cruise release switch. 2. Complete the following in order to remove the cruise release switch from the brake pedal bracket: 1. Rotate the switch counter clockwise. 2. Pull the switch from the retainer. 3. Push the locking tabs inward to release the retainer. Installation Procedure 1. Connect the electrical connector to the cruise release switch. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 525 2. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 530 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 534 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 535 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Harness Routing Views Evaporator Temperature Sensor / Switch: Locations Harness Routing Views Harness Routing Views HVAC Harness Routing 1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Harness Routing Views > Page 541 Evaporator Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the I/P Components 1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 542 Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Evaporator Temperature Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 543 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement Removal Procedure 1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 2. Remove the mounting screw from the evaporator temperature control module. 3. Disconnect the electrical connector from the control module. 4. Cut the evaporator temperature sensor wire near the control module. Note: * Note the mounting position of the evaporative temperature sensor (a, b) and use these measurements upon installation. * If you are replacing only the control module, proceed to Step 4 of the Installation Procedure. 5. Remove the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See: Heating and Air Conditioning/Evaporator Core/Service and Repair). 6. Using needle nose pliers, carefully remove the evaporator temperature sensor from the evaporator core. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 544 1. Install the evaporator temperature sensor to the evaporator core. Place the sensor approximately 3.5 cm (1.4 in) from the side (a) and 5 cm (2 in) from the bottom (b) corner of the evaporator core. Note: Improper wire alignment will pinch and may cut the sensor wires. 2. Align the evaporator temperature sensor wires with the opening in the upper HVAC module case. 3. Install the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See: Heating and Air Conditioning/Evaporator Core/Service and Repair). 4. Cut the evaporator temperature sensor from the replacement assembly. 5. Connect the original sensor wire to the replacement assembly. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Connect the electrical connector to the evaporator temperature control module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the mounting screw to the control module. Tighten the screw to 1.9 Nm (17 lb in). 8. Install the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 549 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 550 Refrigerant Pressure Sensor / Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 551 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 552 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 553 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 554 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views Dimmer Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 560 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 561 Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 562 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views Door Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 567 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 568 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Left Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 569 1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver Right Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 570 1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right Rear Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 571 Door Switch: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left B-Pillar Components (Regular Cab) 1 - Door Jamb Switch - Driver Left B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 572 1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver Right B-Pillar Components (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 573 1 - Door Jamb Switch - Passenger Right B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 574 1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 575 Door Switch: Locations Door Component Views Door Component Views Left Rear Door Frame Components (Extended Cab) 1 - Door Jamb Switch - Driver Right Rear Door Frame Components (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 576 1 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 577 Door Switch: Diagrams Component Connector End Views Door Jamb Switch - Driver Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 578 Door Jamb Switch - Left Rear (Crew Cab) Door Jamb Switch - Right Rear (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 579 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 580 Door Switch: Service and Repair Door Jamb Switch Replacement Removal Procedure 1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch. Installation Procedure 1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 581 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw retaining the door jam switch to the body. Tighten the door jamb switch screw to 1.5 Nm (13 lb in). 4. Close the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Outside Temperature Display Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 589 Outside Temperature Display Sensor: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 590 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 591 Outside Temperature Display Sensor: Service and Repair Ambient Air Temperature Sensor Replacement Removal Procedure 1. Remove the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 2. Disconnect the electrical connector to the ambient air temperature sensor. 3. Release the tabs (1) retaining the sensor to the radiator support bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 592 4. Remove the sensor (1) from the radiator support bracket. Installation Procedure 1. Position the sensor (1) to the radiator support bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 593 2. Install the sensor ensuring the retaining tabs (1) are fully seated to the radiator support bracket. 3. Connect the electrical connector to the ambient air temperature sensor. 4. Install the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 597 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in). 3. Install the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 598 4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 604 Ambient Light Sensor: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 605 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 606 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 607 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Removal Procedure 1. Carefully use a flat-bladed tool, and remove the sensor from the upper portion of the instrument panel (I/P). 2. Disconnect the electrical connector (2) from the sensor ensuring the connector does NOT fall through the hole in the I/P. 3. Remove the sensor from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 608 1. Connect the electrical connector (2) to the sensor. 2. Align the sensor to the I/P for installation. 3. Apply downward pressure to the sensor head in order to seat the sensor to the I/P. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Powertrain Component Views Right Side of the Transmission Components (MA5) 1 - Backup Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 612 Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 613 Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the backup lamp switch electrical connector (1) at the pigtail. 3. Open the tie strap securing the pigtail to the transmission. 4. Remove the backup lamp switch with the aluminum washer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 614 Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install the backup lamp switch with a NEW aluminum washer into the transmission case. Tighten the backup lamp switch to 44 Nm (32 lb ft). 2. Secure the pigtail to the transmission with the tie strap. 3. Connect the backup lamp switch electrical connector (1) at the pigtail. 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 623 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 624 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 625 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 626 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 631 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 632 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 633 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect Brake Light Switch: Recalls Recall 09V310000: Brake Lamp Switch Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon 2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: July 28, 2009 NHTSA CAMPAIGN ID NUMBER: 09V310000 NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 185903 SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year 2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290, and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. REMEDY: Dealers will inspect and replace the necessary components as specified in the recall bulletin free of charge. GM anticipates that parts will be available by February 2010. A special coverage for vehicles registered in all other states will be implemented in the same time frame. In the interim, owners who experience the failure can obtain a free repair, however they will be required to return when the new design part becomes available. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at www.gmownercenter.com. NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 643 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 644 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 645 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 646 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 651 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 652 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 653 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect Brake Light Switch: All Technical Service Bulletins Recall 09V310000: Brake Lamp Switch Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon 2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: July 28, 2009 NHTSA CAMPAIGN ID NUMBER: 09V310000 NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 185903 SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year 2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290, and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. REMEDY: Dealers will inspect and replace the necessary components as specified in the recall bulletin free of charge. GM anticipates that parts will be available by February 2010. A special coverage for vehicles registered in all other states will be implemented in the same time frame. In the interim, owners who experience the failure can obtain a free repair, however they will be required to return when the new design part becomes available. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at www.gmownercenter.com. NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 658 Brake Light Switch: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 659 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 660 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 661 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 662 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 663 Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 664 Brake Light Switch: Adjustments Stop Lamp Switch Adjustment 1. Rotate the switch counterclockwise, allowing the retainer to release. 2. Pull the brake pedal rearward to full stop. Important: Do not move the brake pedal during switch adjustment as this will cause an over-adjusted switch which could cause brake drag. 3. While holding the brake pedal FIRMLY in position rearward, push the switch inward fully until the switch body contacts the brake pedal arm striker plate. At this point the plunger in the switch should be pushed in. 4. Rotate the switch clockwise until a "click" is heard. 5. The switch is properly adjusted when there is 7 mm (0.028 in) clearance between the end of the switch barrel and the striker plate on the brake pedal arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 665 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the stop lamp switch electrical connectors (1). 2. Rotate the switch counterclockwise. 3. Remove the switch from the bracket. 4. Remove the switch from the vehicle. Installation Procedure 1. Position the switch near the bracket. 2. Ensure the switch key-way is properly indexed to the plastic retainer. 3. Install and adjust the switch. Refer to Stop Lamp Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 666 4. Connect the stop lamp switch electrical connectors (1). 5. Check the switch for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views Door Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 674 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 675 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Left Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 676 1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver Right Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 677 1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right Rear Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 678 Door Switch: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left B-Pillar Components (Regular Cab) 1 - Door Jamb Switch - Driver Left B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 679 1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver Right B-Pillar Components (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 680 1 - Door Jamb Switch - Passenger Right B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 681 1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 682 Door Switch: Locations Door Component Views Door Component Views Left Rear Door Frame Components (Extended Cab) 1 - Door Jamb Switch - Driver Right Rear Door Frame Components (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 683 1 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 684 Door Switch: Diagrams Component Connector End Views Door Jamb Switch - Driver Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 685 Door Jamb Switch - Left Rear (Crew Cab) Door Jamb Switch - Right Rear (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 686 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 687 Door Switch: Service and Repair Door Jamb Switch Replacement Removal Procedure 1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch. Installation Procedure 1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 688 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw retaining the door jam switch to the body. Tighten the door jamb switch screw to 1.5 Nm (13 lb in). 4. Close the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Harness Routing Views Hazard Warning Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Harness Routing Views > Page 693 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Harness Routing Views > Page 694 Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 695 Hazard Warning Switch: Diagrams Component Connector End Views Hazard Warning Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 696 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Disconnect the hazard switch electrical connector. Important: Ensure the tabs retaining the switch to the trim plate are released from the back side of the trim panel. 3. Release the tabs retaining the switch to the trim plate. 4. Remove the switch (1) from the trim plate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 697 Installation Procedure 1. Position the switch (1) to the trim plate. 2. Ensure the switch key-way is indexed to the trim plate. 3. Install the switch to the trim plate ensuring the tabs are fully seated. 4. Connect the hazard switch electrical connector. 5. Install the I/P accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views Headlamp Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 702 Headlamp Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 703 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 704 Headlamp Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 705 Headlamp Switch: Service and Repair Headlamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the screw retaining the switch to the instrument panel (I/P). 3. Partially remove the switch from the I/P. 4. Disconnect the switch electrical connector. 5. Remove the switch from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 706 1. Position the switch to the I/P. 2. Connect the electrical connector to the switch. 3. Install the switch to the I/P. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screw retaining the switch to the I/P. Tighten the screw to 2.5 Nm (22 lb in). 5. Install the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component Connector End Views Horn Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 710 Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Removal Procedure Warning: Refer to Servicing the SIR System Warning (See: Restraint Systems/Service Precautions/Servicing the SIR System Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the Inflatable Restraint Steering Wheel module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 3. Remove the horn plunger from the steering column by pressing inward to the stop and by rotating the plunger 90 degrees. 4. Disconnect the screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Connect the screws (1, 4) that secure the contact plate to the steering wheel (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 711 Tighten the screws to 5.5 Nm (49 lb in). 3. Install the horn plunger to the steering column. 4. Install the inflator module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement Multifunction Turn Signal Switch Housing Replacement Removal Procedure 1. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement). 2. Remove the multifunction turn signal switch housing bolts. 3. Remove the multifunction turn signal switch housing. Installation Procedure 1. Install the multifunction turn signal switch housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the multifunction turn signal switch housing bolts. Tighten the bolts to 2.5 Nm (22 lb in). 3. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 717 Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Removal Procedure Note: The turn signal multifunction switch and Inflatable restraint steering wheel module coil are serviced as an assembly. 1. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect any electrical connectors and remove the wiring harness from any retainers as needed. 4. Remove the turn signal multifunction switch bolts. 5. Slide the multifunction turn signal switch off of the steering column. Installation Procedure Note: A new multifunction turn signal switch will come precentered with a centering tab attached. Do NOT remove the centering tab until installation is complete. Failure to follow procedure will cause a misalignment of the multifunction turn signal switch and centering will be required. If reusing the existing multifunction turn signal switch, you must center it. Refer to Inflatable Restraint Steering Wheel Module Coil Centering ( See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures). 1. Slide the multifunction turn signal switch onto the steering column. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 718 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the multifunction turn signal switch bolts. Tighten the bolts to 7 Nm (62 lb in). 3. Route the wire harness assembly down the steering column. 4. Connect any electrical connectors and install the wiring harness through any retainers as needed. 5. Remove the centering tab from the multifunction turn signal switch. 6. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 7. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 725 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 726 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 727 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 728 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 729 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 730 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 731 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 732 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 736 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 737 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 741 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 742 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 746 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 747 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 3. Remove the ECT sensor (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 748 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Install the ECT sensor (1). Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 749 System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 753 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 756 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 757 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 761 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1) from the module cover. 3. Complete the following in order to remove the fuel level sensor (1) from the module bucket: 1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 762 1. Complete the following in order to install the fuel level sensor to the module bucket. 1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into position, ensure the locking tabs are fully engaged. 2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 771 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls MIL ON/DTC's P0451/P0454 Set > Page 777 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views Fuel Tank Pressure Sensor: Locations Harness Routing Views Harness Routing Views Chassis Harness Routing 1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400 (Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views > Page 780 Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Rear of the Frame Components 1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 781 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 782 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor (1). 5. Pull upward in order to remove the sensor from the fuel tank module. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 783 1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4. Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 787 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 788 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 792 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 793 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 794 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 797 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 798 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 799 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 803 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 804 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2) from the intake manifold. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 805 1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the intake manifold. 3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 809 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 810 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Powertrain Component Views Rear of the Transmission Components 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 814 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 815 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 816 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 819 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 820 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 821 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 824 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 825 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 826 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 827 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 828 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 829 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 830 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 831 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 832 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 833 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 834 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 838 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 839 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 840 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 841 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 842 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Powertrain Component Views Left Side of the Transmission Components (MA5) Description 1 - Vehicle Speed Sensor (VSS) Inside the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 846 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 847 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 848 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS with O-ring seal. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 851 Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install the VSS with O-ring seal. Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft). 2. Connect the VSS electrical connector (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 852 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical connector from the vehicle speed sensor. 3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor (1). 6. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 858 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 859 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 860 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 861 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 862 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 863 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 864 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 865 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 869 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 870 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 875 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 876 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 880 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 883 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 884 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding This vehicle has two different types of ignition lock cylinders based on what type of steering column the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder designs. Ignition Lock Cylinder The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side. Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into the case assembly (5). 1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3. The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install this tumbler in the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4 tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8. Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct key into the lock cylinder. All tumblers (1) should be flush with the housing of the lock cylinder. 9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM Super Lube GM P/N 12346241 or equivalent light lithium grease. 10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front face of the rotor. If the slide piece is installed incorrectly, the key cannot insert into the rotor due to no access to the ramp. 11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock cylinder housing. Ensure that the actuator lever is inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should pivot on the pin against spring tension. 12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side with the security plug (3) faces to the left of the key head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 890 13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the center of the lock cylinder housing (1) and hold it. Insert the coded lock cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the housing. 15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward slightly. The key should be able to be removed and the lock cylinder should remain in the housing. 16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the lock cylinder housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 891 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4. Remove the ignition lock cylinder case. Installation Procedure 1. Install the ignition lock cylinder case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition switch, a passlock relearn will be needed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining pin down. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 892 5. Pull the ignition lock cylinder away from the steering column. Installation Procedure 1. Install the ignition lock cylinder by performing the following procedure: 1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until the retaining pin locks it in place. 2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 896 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 897 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 898 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 901 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 902 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 903 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views Impact Sensor: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 909 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 910 Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 911 Impact Sensor: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 912 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 913 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 914 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 915 Inflatable Restraint Passenger Presence System (PPS) Sensor Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 916 Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 3. Loosen the fasteners (1) retaining the front discriminating sensors to the radiator support. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 919 4. Remove the sensor assembly from the radiator support. 5. Position the sensor assembly, to gain access to the electrical connector. 6. Remove the connector-position assurance (CPA) from the sensor electrical connector. 7. Disconnect the sensor electrical connector. 8. Remove the sensor from the vehicle. Installation Procedure 1. Remove any dirt, grease, or other impurities from the mounting surfaces. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 920 2. Position the sensor near the radiator support. 3. Connect the sensor electrical connector. 4. Install the CPA to the sensor electrical connector. 5. Install the sensor assembly to the radiator support. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 921 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the 2 fasteners (1) retaining the discriminating sensor assembly to the radiator support. Tighten the bolts to 9 Nm (80 lb in). 7. Install the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 922 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Fold back the carpet in order to gain access to the sensor. Refer to Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 3. Disconnect the electrical connector. 4. Remove the nuts securing the rollover sensor to the floor panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 923 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the nuts securing the rollover sensor to the floor panel. Tighten the screws to 10 Nm (88 lb in). 2. Connect the electrical connectors. 3. Install the carpet. Refer to Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 4. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 924 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor to the door. 5. Disconnect the impact sensor electrical connector from the side impact sensor. 6. Remove the side impact sensor from the door. Installation Procedure 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 925 2. Position the side impact sensor horizontally to the door. 3. Connect the electrical connector to the side impact sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screws which retain the side impact sensor to the door. Tighten the screws to 9 Nm (79 lb in). 5. Fully seat the water deflector to the door. 6. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 7. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Locations Seat Belt Tension Sensor: Locations Passenger Compartment/Roof Component Views Passenger Seat Components - 1 of 2 1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 933 Seat Occupant Sensor: Locations Passenger Compartment/Roof Component Views Passenger Seat Components - 2 of 2 1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 934 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Removal Procedure Warning Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 1. Remove the seat cushion trim cover and pad. 2. Disconnect the electrical connectors. 3. Remove the bolts that retain the electronic control unit (ECU) (1) from the bottom of the passenger seat cushion frame. 4. Remove the pressure switch (2) from the bottom of the passenger seat cushion frame. 5. Remove the push-in retainers (1) that hold the bladder to the seat cushion frame. 6. Remove the inflatable restraint passenger presence system from the seat. Installation Procedures 1. Install the inflatable restraint passenger presence system to the seat. 2. Install the push-in retainers (1) that hold the bladder to the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 935 3. Install the pressure sensor (2) to the bottom of the passenger seat cushion frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolts that retain the ECU (1) to the bottom the passenger seat cushion frame. Tighten the bolts to 2 Nm (18 lb in). 5. Connect the electrical connectors. 6. Install the seat cushion trim cover and pad. 7. Re-zero the inflatable restraint passenger presence system. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Passenger Seat Components - 1 of 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 939 1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger Under the Passenger Seat Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 940 1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger (KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1) 7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 941 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Left Inflatable Restraint Seat Position Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 942 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement (Power Seat) Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). 2. Ensure that the seat is in the full rear position. 3. Locate the seat position sensor (1) under the seat on the inside of the inner seat rail. 4. Disconnect the electrical connector (3) from the seat position sensor (1). 5. Remove the 2 nuts (2) that retain the seat position sensor to the seat rail. 6. Remove the seat position sensor from the seat. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 943 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the seat position sensor (1) to the seat rail with 2 nuts (2). Tighten the seat position sensor nuts to 9 Nm (79 lb in). 2. Connect the electrical connector (13) to the seat position sensor (1). 3. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 948 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 949 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 950 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 951 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding This vehicle has two different types of ignition lock cylinders based on what type of steering column the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder designs. Ignition Lock Cylinder The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side. Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into the case assembly (5). 1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3. The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install this tumbler in the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4 tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8. Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct key into the lock cylinder. All tumblers (1) should be flush with the housing of the lock cylinder. 9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM Super Lube GM P/N 12346241 or equivalent light lithium grease. 10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front face of the rotor. If the slide piece is installed incorrectly, the key cannot insert into the rotor due to no access to the ramp. 11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock cylinder housing. Ensure that the actuator lever is inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should pivot on the pin against spring tension. 12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side with the security plug (3) faces to the left of the key head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 957 13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the center of the lock cylinder housing (1) and hold it. Insert the coded lock cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the housing. 15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward slightly. The key should be able to be removed and the lock cylinder should remain in the housing. 16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the lock cylinder housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 958 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4. Remove the ignition lock cylinder case. Installation Procedure 1. Install the ignition lock cylinder case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition switch, a passlock relearn will be needed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining pin down. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 959 5. Pull the ignition lock cylinder away from the steering column. Installation Procedure 1. Install the ignition lock cylinder by performing the following procedure: 1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until the retaining pin locks it in place. 2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 967 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 968 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 969 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 970 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 971 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 972 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 979 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 980 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 981 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 982 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 983 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 984 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 990 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 991 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 992 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 993 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 994 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 997 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the body control module (BCM) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 998 Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement Tire Valve Stem Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 999 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Inside the Transmission Components (M30) 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1005 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30) Description Location Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1009 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1010 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1011 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1012 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1013 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Sensor (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 1024 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position switch (1). 2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 1025 1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1), until the locking tabs (2) are fully engaged. 2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the following in order to adjust the clutch pedal position switch (1). 1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2. Depress the clutch pedal all the way to the floor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views Power Window Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 1031 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Right Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 1032 1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door Harness) Left Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 1033 1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 1034 Power Window Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 1035 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Left Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 1036 1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear (A31) 5 - Door Lock Actuator - Left Rear (AU3) Right Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 1037 1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1038 Power Window Switch: Diagrams Component Connector End Views Door Lock/Window Switch - Driver X1 (A31/AU3) Door Lock/Window Switch - Driver X2 (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1039 Door Lock/Window Switch - Passenger (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1040 Window Switch - Left Rear (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1041 Window Switch - Right Rear (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1042 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel opening. 4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate. 7. If replacing only the switch plate, retain the switches for transfer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 1045 Installation Procedure 1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the switches (2, 5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 1046 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 1047 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the switch plate up and out of the door trim panel. 3. Disconnect the electrical connectors from the switch module. 4. Remove the switch plate assembly from the vehicle. 5. If replacing only the switch module, remove the module from the switch plate. 6. If replacing only the switch plate, retain the switch module for transfer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 1048 1. Install the switch module to the switch plate. 2. Connect the electrical connector to the switch module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1054 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1055 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1056 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1057 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1058 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1059 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1060 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening Specifications Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening Specifications > Page 1063 Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening Specifications > Page 1064 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1067 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1068 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1069 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1070 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1071 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1072 path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1073 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights. 1. Make sure that the vehicle is on a level surface, such as an alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressure to the pressures shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID). 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure that the rear compartment is empty except for the spare tire. 6. Close the doors and he hood. Z Height Measurement The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Jounce the front and rear suspension to obtain at least 38 mm (1.5 in) deflection, then allow the vehicle to settle. Important: The left and right Z height difference should be no more than 12 mm (0.47 in). 1. Set the top edge of the level on the reference surface (Point A) of the steering knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1074 2. With the level on the steering knuckle (C), extend the level directly under the rear of the rear of the front attachment bolt of the lower control arm (A). 3. While keeping the level in contact with the knuckle reference surface, adjust the level up or down until the bubble indicates it is horizontally level. 4. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your first measurement. 5. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the front end of the rear attachment bolt of the lower control arm (B). 6. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your second measurement. 7. Average the 2 readings (add them together, and then divide by 3) and this result is your final Z height number. 8. Repeat steps 1 through 7, a total of 3 times, writing down the results. 9. Average the results (add them together, and then divide by 3) and this result is your final Z height number. 10. Compare your Z height number with the Service Information Z height specification. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). Z Height Adjustment Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1075 1. For vehicles equipped with a torsion bar suspension turn the torsion bar adjuster bolt (1) clockwise to raise the and counterclockwise to lower the height adjustment. 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: The left and right D height difference should be no more than 12 mm (0.47 in.) 1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. D Height shall be measured as the perpendicular distance from the inside lip of the jounce bumper cup flange to the jounce bumper contact pad, or top of the rear axle "tube" when a jounce bumper pad is not used. 5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). 10. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) and Tire Diagnosis Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering and Suspension/Steering/Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1078 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Special Tools J 45938 Alignment Socket 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). For an accurate reading, do not push or pull on the tires during the alignment process. 2. Determine the caster angle (2). Be sure to compensate for frame angle where required. 3. Determine the positive camber (2) or negative camber (3) angle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1079 4. The 4WD and 2WD Z71 vehicles are adjusted at the upper control arm. 5. The 2WD vehicles are adjusted at the lower control arm. 6. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 7. Loosen the control arm cam adjustment bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Using the J 45938 adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt in order to ensure the cam bolt position does not change while tightening the nut. * Tighten the 2WD cam nuts to 155 Nm (114 lb ft). * Tighten the 4WD cam nuts to 155 Nm (114 lb ft). 9. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications). When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1080 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the tie rod. 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the jam nut on the tie rod to 70 Nm (52 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Page 1081 Alignment: Tools and Equipment Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure (Ignition ON, engine OFF)............................................................................................. ..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than 34 kPa (5 psi) in 1 minute Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1086 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1087 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Fuel Pressure Gage * J 37287 - Fuel Line Shut-Off Adapters Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal). 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1088 ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gage. The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test normal, replace the fuel sender. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Return Line/Service and Repair) * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1093 4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6. Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing. Installation Procedure 1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to engage the duct to the ball stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the air cleaner outlet duct clamp (1) at the throttle body. Tighten the clamp to 3.5 Nm (31 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1094 4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing. Tighten the clamp to 3.5 Nm (31 lb in). 5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Release the air cleaner upper housing retainer clips (1). 3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1098 1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper housing (1). 3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1104 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1105 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1106 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1107 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1114 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. * Twist each spark plug 1/2 turn. * Pull only on the boot in order to remove the wire from each spark plug. 2. Remove the spark plug wire from the ignition coil. * Twist each spark plug boot 1/2 turn. * Pull only on the boot in order to remove the wires from the ignition coil. Installation Procedure 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the wires for proper installation: * Push sideways on each boot in order to inspect the seating. * Reinstall any loose boot. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1123 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1124 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1130 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 1131 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1132 Spark Plug: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1133 Spark Plug: Application and ID Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1134 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1) - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3,4). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1135 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A looses center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1136 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the spark plug. Tighten the plug to 20 Nm (15 lb ft). 5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1140 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1148 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1149 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1150 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1151 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump - The generator - The A/C compressor - The engine cooling fan - The water pump, if belt driven The drive belt system may use 2 belts. The drive belt (1) is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plies containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system has an idler pulley, which is used to add wrap to the adjacent pulleys. A/C Compressor Drive Belt Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1152 The outward appearance of the belt (1) is similar to the current design serpentine belt. The reinforcing cord provides its unique qualities. The belt cord is made of a polyamid material. The polyamid cord is more elastic than the more traditional aramid or polyester cord designs. A tensioner is not needed. Polyamid cord, when combined with a more elastic backing compound, ensures the belt is able to maintain the specified tension within the specified range of usage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1155 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1156 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1157 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1158 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1159 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1160 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1161 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory Removal Procedure 1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1164 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Start the vehicle and inspect the drive belt for proper operation. 10. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1165 Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement Air Conditioning Compressor Belt Replacement Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). 2. Remove the cooling fan. Refer to Fan Replacement (LH8) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (LLV, LLR) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys. Installation Procedure 1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install the belt installation tool (3) onto the balancer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1166 3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4. Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light tension to the belt. 5. Position the lower portion of the belt (1) with the ribbed area facing forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1167 6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull the belt (2) forward. Ensure that the ribbed area of the belt remains facing forward and the belt aligns properly to the A/C pulley. 7. Inspect the drive belt (1) for proper installation and alignment. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1168 8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install the cooling fan. Refer to Fan Replacement (LH8) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (LLV, LLR) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1174 4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6. Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing. Installation Procedure 1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to engage the duct to the ball stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the air cleaner outlet duct clamp (1) at the throttle body. Tighten the clamp to 3.5 Nm (31 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1175 4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing. Tighten the clamp to 3.5 Nm (31 lb in). 5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Release the air cleaner upper housing retainer clips (1). 3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1179 1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper housing (1). 3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Note: Do not pull on the boot portion of the cable. 2. Complete the following in order to disconnect the range selector cable (3) from the transmission range selector lever ball stud: 1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever (1). 2. Pry the range selector cable end (5) away from the range selector lever (1). 3. Remove the bolts securing the transmission range selector cable bracket to the transmission. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1183 4. Position the transmission range selector cable bracket aside for clearance while lowering the pan. 5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to drain into the container. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1184 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for root cause diagnosis: * Bronze slivers indicating bushing wear * Clutch material * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces of the old gasket material must be removed. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1185 1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the container used to catch the used transmission fluid from under the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1186 7. Position the transmission range selector cable bracket to the transmission. 8. Install the transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment (5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) ( See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments). 10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) and Fluid Capacity Specifications (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Specifications/Capacity Specifications). 12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1192 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1193 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1194 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1195 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1200 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1201 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter. Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1202 Tighten the drain plug to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Service Intervals) and Fluid and Lubricant Recommendations ( See: Service Intervals). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (With LH8) (5.3L) Removal Procedure 1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Otherwise proceed to the next step. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1207 7. Remove the coolant air bleed pipe (307) and seals (308). 8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed covers (313) and seals (308), if required. 10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1208 Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309) and tighten to 12 Nm (106 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1209 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required and tighten to 12 Nm (106 lb in). 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement Tools Required * J 38185 Hose Clamp Pliers * J 43181 Heater Line Quick Connect Release Tool Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 43181 , release the inlet heater hose quick connect (1) from the heater core inlet. 3. Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Remove the heater inlet hose (3) from the inlet hose fitting (6) at the engine block. 5. Remove the heater inlet hose (3). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1214 1. Apply coolant to the end of the heater inlet hose (5). Important: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose (3) to the inlet hose fitting (6) at the engine block. 3. Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Install the heater inlet hose (3) to the heater core inlet. 5. Press the quick connect (1) onto the heater core inlet until fully seated. 6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1215 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 3. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 4. Using the J 38185 disconnect the outlet hose from the heater core outlet tube. 5. Remove the heater outlet hose from the heater core. 6. Position the outlet heater hose clamp (6) at the water pump using J 38185 . 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 . 4. Install the heater outlet hose to the heater core. 5. Position the outlet heater hose clamp at the heater core using J 38185 . 6. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1216 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 8. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1217 Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1218 Heater Hose: Service and Repair Heater Inlet Pipe Replacement Heater Inlet Pipe Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 38185 , reposition the heater hose outlet clamp from the heater pipe inlet. 3. Remove the heater hose outlet from the heater pipe inlet. 4. Remove the exhaust heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR) (). 5. Remove the heater inlet pipe bolt. 6. Remove the heater inlet pipe. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1219 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3. Install the heater hose outlet to the heater pipe inlet. 4. Using the J 38185 , reposition the heater hose outlet clamp to the heater pipe inlet. 5. Install the exhaust heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR) (). 6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1220 Heater Hose: Service and Repair Heater Outlet Pipe Replacement Heater Outlet Pipe Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 38185 , reposition the heater hose inlet clamp from the heater pipe outlet. 3. Remove the heater hose inlet from the heater pipe outlet. 4. Loosen the heater pipe outlet. 5. Remove the heater pipe outlet. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1221 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3. Install the heater hose inlet to the heater pipe outlet. 4. Using the J 38185 , reposition the heater hose inlet clamp to the heater pipe outlet. 5. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise Under Heavy Load Hose/Line HVAC: Customer Interest A/C - Moan/Whine Noise Under Heavy Load TECHNICAL Bulletin No.: 09-01-38-002 Date: May 14, 2009 Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose With Updated Design) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped with Engine RPO LH8 Condition Some customers may comment on a moan and/or a whine type noise when the A/C compressor is engaged during high system loads. These high load operating conditions include high ambient temperatures, extended periods of idle operation and towing applications. The noise will stop immediately when the compressor is disengaged. Cause This condition may be caused by the factory installed A/C suction hose lacking sufficient noise dampening. Correction Install a new A/C suction hose assembly. This new hose assembly has an improved noise dampening design. Refer to Suction Hose Replacement (LH8) in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise Under Heavy Load Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Whine Noise Under Heavy Load TECHNICAL Bulletin No.: 09-01-38-002 Date: May 14, 2009 Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose With Updated Design) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped with Engine RPO LH8 Condition Some customers may comment on a moan and/or a whine type noise when the A/C compressor is engaged during high system loads. These high load operating conditions include high ambient temperatures, extended periods of idle operation and towing applications. The noise will stop immediately when the compressor is disengaged. Cause This condition may be caused by the factory installed A/C suction hose lacking sufficient noise dampening. Correction Install a new A/C suction hose assembly. This new hose assembly has an improved noise dampening design. Refer to Suction Hose Replacement (LH8) in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement Discharge Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1237 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1238 Hose/Line HVAC: Service and Repair Suction Screen Replacement Suction Screen Replacement Tools Required J 44551 Suction Screen Kit Removal Procedure Important: Suction screens are intended to be installed in the suction hose after a major compressor failure. 1. Remove the A/C suction hose from the A/C compressor. Refer to Suction Hose Replacement (LH8) (See: Suction Hose Replacement)Suction Hose Replacement (LLV, LLR) (See: Suction Hose Replacement). 2. Using the J-44551-9 Universal Removal Tool, place the tip of the tool under the inside edge of the compression band of the suction screen and the cushioning fulcrum pad against the open end of the hose or manifold fitting. Important: Do not damage the end of the hose or manifold. 3. Pry upward on the band and move the tool around the diameter of the screen as necessary to remove the screen. Installation Procedure 1. Using a caliper that reads to 3 decimal places, measure the ID of the suction hose or manifold suction fitting. To determine the correct size screen for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See: Heating and Air Conditioning/Specifications/Mechanical Specifications/Heating, Ventilation, and Air Conditioning/Compressor Suction Screen and Tool Selection Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1239 2. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt: * The brass Universal Mandrel is for use on hose fittings with a smooth bore where the screen installs flush with the end of the fitting. * The 11.96 mm (0.471 in) Mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with an internal hourglass shape where the screen installs at the recessed, reduced diameter point. 3. Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting. 4. Place the suction hose fitting or suction hose side of the manifold into the installation tool fixture J-44551-5 (3) so it is supported by the tools legs. Important: Correct placement of the J-44551-5 is critical. 5. Lubricate the A/C suction screen with the applicable refrigerant oil. 6. Align the screen (2), basket first; into the suction hose bore then hand tighten the bolt until contact is made between the hose, screen and tool. 7. Turn the bolt of the installation tool clockwise pressing the screen into the bore until the mandrel shoulder contacts the end of the hose fitting. 8. Unscrew the bolt and remove the installation tool from the hose or manifold. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1240 Important: Clean the surface to be used for attaching the label. 9. Install the J-44551-1 Suction Screen Notification Label. 10. Install the A/C hose to the A/C compressor. Refer to Suction Hose Replacement (LH8) (See: Suction Hose Replacement)Suction Hose Replacement (LLV, LLR) (See: Suction Hose Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions > Page 1244 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet and Outlet Hose Replacement (LH8) (5.3L) Removal Procedure 1. Remove as much power steering fluid from the power steering fluid reservoir as possible. 2. Remove the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Place drain pans under the vehicle as needed. 4. Disconnect the power steering gear inlet and outlet hose (1) from the power steering pump and power steering fluid reservoir assembly. 5. Remove the power steering gear inlet and outlet hose bracket bolts (2). 6. Remove the power steering gear inlet and outlet hose retaining plate bolt (1). 7. Disconnect the power steering gear inlet and outlet hose (3) from the steering gear and remove it from the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions > Page 1245 8. Clean the power steering gear inlet and outlet hose ports at the steering gear of any debris. 9. Transfer any parts as needed. Installation Procedure 1. Install the power steering gear inlet and outlet hose (3) to the vehicle and connect it to the steering gear. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the power steering gear inlet and outlet hose retaining plate bolt (1) and tighten to 12 Nm (106 lb in). 3. Install the power steering gear inlet and outlet hose bracket bolts (2) and tighten to 9 Nm (80 lb in). 4. Connect the power steering gear inlet and outlet hose (1) to the power steering pump and power steering fluid reservoir assembly. Tighten the fitting to 25 Nm (18 lb ft). 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Install the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 7. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions > Page 1246 Steering/Power Steering Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1251 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications HYDRAULIC BRAKE SYSTEM DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... .............................................. 13.7 quarts (13.0 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1263 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: Give freezing protection down to -34°F (-37°C). Give boiling protection up to 265°F (129°C). Protect against rust and corrosion. Help keep the proper engine temperature. Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 1268 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID Pan Removal ......................................................................... ..................................................................................................................... 4.7 liters (5.0 qts) Overhaul .............................................................................................................................................. ................................................... 10.6 liters (11.0 qts) With 245 mm Torque Converter Dry Fill ......... .............................................................................................................................................................. ................................ 8.3 liters (8.8 qts) With 258 mm Torque Converter Dry Fill ................................ .............................................................................................................................................................. ......... 8.8 liters (9.3 qts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1271 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSAXLE FLUID DEXRON-VI Automatic Transmission Fluid. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1272 Fluid - A/T: Testing and Inspection Transmission Fluid Check This procedure checks the transmission fluid level, as well as the condition of the fluid itself. Caution: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Before checking the fluid level, perform the following: 1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 RPM for at least 1 minute. Slowly release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the appropriate check procedure. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Cold Check Procedure Note: * Use the cold check procedure only as a reference to determine if the transmission has enough fluid to be operated safely until a hot check procedure can be made. The hot check procedure is the most accurate method to check the fluid level. Perform the hot check procedure at the first opportunity. * Use this cold check procedure to check fluid level when the TFT is between 27-32°C (80-90°F). 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out again. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check line, add only enough fluid as necessary to bring the level into the COLD line. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the transmission reaches a normal operating temperature between 82-93°C (180-200°F). Hot Check Procedure Note: Use this procedure to check the transmission fluid level when the TFT is between 82-93°C (180-200°F). The hot check procedure is the most accurate method to check the fluid level. The hot check should be performed at the first opportunity in order to verify the cold check. The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick tip pointing down and check both sides of the dipstick. Read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the transmission temperature is between 82-93°C (180-200°F), add or drain fluid as necessary to bring the level into the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. Note: To assist in reaching the correct temperature range of 82-93°C (180-200°F), drive the vehicle in second gear at no more than 65 mph until the desired temperature is reached. 7. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Transmission and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1273 Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Fluid Leak Diagnosis). 8. If the fluid level is in the acceptable range, push the dipstick back into the dipstick tube all the way, and then flip the handle down to lock the dipstick in place. 9. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid was changed. Fluid Condition Inspection Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/Engine Coolant/Water in Transmission). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1274 Fluid - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Note: Do not pull on the boot portion of the cable. 2. Complete the following in order to disconnect the range selector cable (3) from the transmission range selector lever ball stud: 1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever (1). 2. Pry the range selector cable end (5) away from the range selector lever (1). 3. Remove the bolts securing the transmission range selector cable bracket to the transmission. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1275 4. Position the transmission range selector cable bracket aside for clearance while lowering the pan. 5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to drain into the container. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1276 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for root cause diagnosis: * Bronze slivers indicating bushing wear * Clutch material * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces of the old gasket material must be removed. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1277 1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the container used to catch the used transmission fluid from under the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1278 7. Position the transmission range selector cable bracket to the transmission. 8. Install the transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment (5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) ( See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shift Linkage/Shift Cable/Adjustments). 10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) and Fluid Capacity Specifications (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Specifications/Capacity Specifications). 12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Fluid .................................................................................................................. ................................................. 2.2 liters (2.3 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1283 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION FLUID SAE 75W-90, API AI-A or GL-3 GM Part No. U.S. 89021806, in Canada 89021807. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1284 Fluid - M/T: Service and Repair Transmission Fluid Replacement Draining Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Clean away all dirt and debris from the transmission fluid drain plug area. 3. Position an appropriate container under the transmission. 4. Remove the transmission fluid drain plug and washer. Discard the washer. Allow the transmission fluid to drain into the container. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 5. Install the transmission fluid drain plug and NEW washer. Tighten the drain plug to 37 Nm (27 lb ft). 6. Remove the container used to catch the used transmission fluid from under the vehicle. Filling Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1285 1. Clean away all dirt and debris from the transmission fluid fill plug area. 2. Remove the transmission fluid fill plug and washer. Discard the washer. 3. Fill the transmission to just below the bottom of the fill plug hole with the recommended fluid. Refer to Lubrication Specifications (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Specifications/Fluid Type Specifications). 4. Install the transmission fluid fill plug and NEW washer. Tighten the fill plug to 37 Nm (27 lb ft). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DIFFERENTIAL FLUID Front Axle ...................................................................................................... ......................................................................................... 1.5 liters (3.2 pints) Rear Axle 8.0 inch ...... .............................................................................................................................................................. ............................... 1.7 liters (3.6 pints) 8.6 inch ................................................................................ ................................................................................................................. 2.03 liters (4.3 pints) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1290 Fluid - Differential: Fluid Type Specifications FRONT AND REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Ensure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Remove the engine protection shield (EPS), if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 5. Clean the area around the front axle fill plug. 6. Remove the front axle fill plug and the washer. 7. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". Note: Ensure that the pipe cleaner is resting on the bottom threads of the fill hole. 8. Insert the pipe cleaner into the fill plug opening with the stem "L" is facing down. 9. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The oil level should be between 0-8 mm (0-0.4 in) below the fill plug opening. 10. If the level is low, add fluid until the level is within the proper fluid level specification. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (See: Service Intervals). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Install the fill plug and the washer and tighten the plug to 32 Nm (24 lb ft). 12. Install the EPS, if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 13. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.0 Inch Axle) Rear Axle Lubricant Level Inspection (8.0 Inch Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1293 7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6 Inch Axle) Rear Axle Lubricant Level Inspection (8.6 Inch Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1294 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Ensure that the vehicle is level. 3. Remove the engine protection shield (EPS), if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Remove the drain plug. 5. Drain axle fluid into a suitable container. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the drain plug and tighten to 32 Nm (24 lb ft). 7. Remove the fill plug. 8. Fill the drive axle with the proper fluid. Refer to Fluid and Lubricant Recommendations (See: Service Intervals). 9. Inspect the fluid level. Refer to Front Axle Lubricant Level Inspection (See: Procedures/Front Drive Axle). 10. Install the fill plug and tighten to 32 Nm (24 lb ft). 11. Install the EPS, if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 12. Lower the vehicle. Rear Axle Lubricant Replacement (8.0 Inch Axle) Rear Axle Lubricant Replacement (8.0 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Cover/Service and Repair). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Cover/Service and Repair). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Service Intervals) and Adhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Rear Axle Lubricant Replacement (8.6 Inch Axle) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1295 Rear Axle Lubricant Replacement (8.6 Inch Axle) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Cover/Service and Repair). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Cover/Service and Repair). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Service Intervals) and Adhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1296 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) /. 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1301 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1302 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1305 Engine Oil: Fluid Type Specifications ENGINE OIL Look for three things: 1. Use only an oil that meets GM Standard GM6094M. 2. Temperatures above -20°F (-29°C), SAE 5W-30 is best for the vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50 or any other viscosity grade oil not recommended. 3. American Petroleum Institute (API) starburst symbol Oils meeting these requirements should have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Notice: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by the vehicle warranty. COLD TEMPERATURE OPERATION If in an area of extreme cold, where the temperature falls below -20°F (-29°C), use either an SAE 5W-30 synthetic oil or an SAE 0W-30 engine oil. Both provide easier cold starting for the engine at extremely low temperatures. Always use an oil that meets the required specification, GM6094M. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to the oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is needed for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1306 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1307 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter. Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1308 Tighten the drain plug to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Service Intervals) and Fluid and Lubricant Recommendations ( See: Service Intervals). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1316 Refrigerant: Fluid Type Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1321 Refrigerant Oil: Fluid Type Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel Brake Bleeding: Customer Interest Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 1330 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 1331 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel Brake Bleeding: All Technical Service Bulletins Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 1337 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 1338 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 1339 Brake Bleeding: By Symptom Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 1340 List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 1341 Disclaimer Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 1342 Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 1343 For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 1344 Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 1345 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure Antilock Brake System Automated Bleed Procedure Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: ). 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 1348 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Service Intervals). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Service Intervals). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 1349 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Pressure Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent. Add GM approved brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 1350 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling) 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure (See: ). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 1351 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement) * Wheel Cylinder Replacement (See: Brakes and Traction Control/Drum Brake System/Wheel Cylinder/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement) * Wheel Cylinder Replacement (See: Brakes and Traction Control/Drum Brake System/Wheel Cylinder/Service and Repair) , if equipped Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 1352 * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 1356 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start Fuse: Customer Interest Electrical - Dead Battery/No Crank/No Start TECHNICAL Bulletin No.: 08-06-03-010 Date: September 30, 2008 Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC) Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System Message (Install 125 Amp Mega Fuse) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3 Condition Some customers may comment on the following conditions: ^ The battery runs down. ^ The engine will not crank. ^ The engine will not start. ^ The Instrument Panel Cluster charge indicator turns on. ^ The Driver Information Center displays a Service Charge System message. Cause This condition may be caused by an open Mega Fuse in the underhood electrical center. Correction Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 1366 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start TECHNICAL Bulletin No.: 08-06-03-010 Date: September 30, 2008 Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC) Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System Message (Install 125 Amp Mega Fuse) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3 Condition Some customers may comment on the following conditions: ^ The battery runs down. ^ The engine will not crank. ^ The engine will not start. ^ The Instrument Panel Cluster charge indicator turns on. ^ The Driver Information Center displays a Service Charge System message. Cause This condition may be caused by an open Mega Fuse in the underhood electrical center. Correction Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 1372 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 1378 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 1379 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 1385 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 1386 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block Fuse: Locations Engine Compartment Fuse Block ENGINE COMPARTMENT FUSE BLOCK The engine compartment fuse block is located on the driver side of the engine compartment. To remove the cover, push in on the tab on the end of the cover and lift. To reinstall the cover, line up the tab and push down on the cover until the tab clicks into place. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1389 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1390 The trailer brake relay is located on the bottom side of the battery harness. FUSES ................................................................................................................................................. ..................................................................... USAGE O2 SNSR .......................................................................................................................................... Oxygen Sensors, Air Injection Reactor (AIR) Relay A/C .............................................................................................................................................................. Air Conditioning Control Head, Power Seats A/C CMPRSR ............................................................... ...................................................................................................... Air Conditioning Compressor ABS .................................................................................................... Antilock Brake System (ABS), ABS Module, Four-Wheel Drive, Gravity Sensor ABS 1 .............................................................................. ................................................................................................................... ABS 1 (ABS Logic) ABS 2 .............................................................................................................................................................. ................................... ABS 2 (ABS Pump) AUX PWR 1 ..................................................................... ................................................................................................................... Accessory Power 1 AUX PWR 2 ................................................................................................................................................. ....................................... Accessory Power 2 BCK/UP ....................................................................... .............................................................................................................................. Back-up Lights BLWR .................................................................................................................................................. .............................................. Climate Control Fan CLSTR ................................................................. ................................................................................................................................................... Cluster CNSTR VENT ......................................................................................................................... ............................................. Fuel Canister Vent Solenoid CRUISE ............................................... Cruise Control Switch, Inside Rearview Mirror, Transfer Case Control Module, Brake Switch, Clutch Disable DR/LCK .................................................................................................................................. ....................................... Power Door Locks (If Equipped) DRL ......................................................... ................................................................................................................................... Daylight Running Lamps ERLS .......................................................................................... Mass Air Flow (MAF) Sensor, Can Purge Solenoid, Air Injector Reactor (AIR) Relay ETC ....................................... ...................................................................................................................................... Electronic Throttle Control (ETC) FOG/LAMP ...................................................................................................... ......................................................................... Fog Lamps (If Equipped) FRT PRK LAMP ....................................................................... Front Park/Turn Lamps, Driver and Passenger Side Power Window Switches Lighting FRT/AXLE ..................................................................................... .................................................................................................... Front Axle Actuator FSCM .............. .............................................................................................................................................................. ....... Fuel System Control Module BACKUP LAMP ............................................................................. ............................................................................................................ Backup Lamp HORN .............. .............................................................................................................................................................. ............................................ Horn HTD/SEAT ..................................................................................... .......................................................................................... Heated Seat (If Equipped) IGN ........................................................... Ignition, Clutch Starter Switch, Neutral Safety Back-Up Switch, Ignition Coils 1-5, Air Conditioning Relay INJ ......................................................................... ............................................................................................................................................... Injectors LT HDLP .............................................................................................................................................. .......................................... Driver Side Headlamp PCM B .................................................................. ......................................................................................................... Power Control Module (PCM) B PCMI .................................................................................................................................................... ............................. Power Control Module (PCM) PWR/SEAT ...................................................................................................................................................... Power Seat Circuit Breaker (If Equipped) PWR/WNDW ..................................................................... ............................................................................................... Power Windows (If Equipped) RDO .... .............................................................................................................................................................. ........................................................ Radio REAR PRK LAMP .............................................................................................. Rear Parking Lamp 1, Passenger Side Taillamp, License Plate Lamps REAR PRK LAMP2 ................ Driver Side Rear Taillamp, Passenger Side Airbag Indicator Lighting, Instrument Panel Dimming Power (2WD/4WD switch lighting) RT HDLP ............................................................................................................................................. ..................................... Passenger Side Headlamp RVC ................................................................... ...................................................................................................................... Regulated Voltage Control S/ROOF .................................................................................................................................. ........................................................ Sunroof (If Equipped) STOP ....................................................... ........................................................................................................................................................ Stop Lamps STRTR ............................................................................................................................ ............................................................... Starter Solenoid Relay TBC ................................................ ............................................................................................................................................... Truck Body Controller TCM ........................................................................................................................... ........................................................ Transmission Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1391 TCCM .................................................................................................................................................. .............................. Transfer Case Control Module TRAILER BRAKE ................................................ ....................................................................................................................................... Trailer Brake TRANS ................................................................................................................................................ .......................................... Transmission Solenoid TRN/HAZRD FRT ..................................................................................................................................... Turn/Hazard/Courtesy/Cargo Lamps/Mirrors TRN/HAZRD REAR ...................................................... ............................................................................................................ Rear Turn/Hazard Lights VSES ................................................................................................................................................... ................. Vehicle Stability Enhancement System WPR .................................................................... ..................................................................................................................................................... Wiper WSW ......................................................................................................................................... ...................................................... Wiper/Washer Switch RELAYS .............................................................................................................................................. .................................................................... USAGE A/C CMPRSR ...................................................................................................................................... ............................... Air Conditioning Compressor BEAM SEL ............................................................ ................................................................................................................................... Beam Selection DRL ..................................................................................................................................................... ....................................... Daylight Running Lamps FOG/LAMP .......................................................... ..................................................................................................................... Fog Lamps (If Equipped) BK UP LP ............................................................................................................................................ ...................................................... Back Up Lamp HDLP ................................................................... ............................................................................................................................................ Headlamps HORN ............................................................................................................................... ......................................................................................... Horn IGN 3 HVAC ................................................................................................. Ignition 3, Climate Control, Climate Control Head Fuse, Power Seat Fuse PRK/LAMP ............................................................................................................................................. Front Parking Lamp Fuse, Rear Parking Lamps PWR/TRN ................................................................................................................ Powertrain, Electronic Throttle Control Fuse, Oxygen Sensor Fuse RAP ................................................................................ Retained Accessory Power (Power Window Fuse, Wiper/Washer Switch Fuse), Sunroof Fuse RUN/CRNK ............ Run/Crank, Airbag System Fuse, Cruise Control Fuse, Ignition Fuse, Back-Up Lamps, ABS Fuse, Front Axle, PCM-1, Injectors Fuse, Transmission Fuse, ERLS STRTR ................................................................................................................................................. ................................... Starter Relay (PCM Relay) VSES ................................................................... ................................................................................................. Vehicle Stability Enhancement System WPR ....................................................................................................................................... ................................................................. Wipers (On/Off) WPR 2 ..................................................... .......................................................................................................................................... Wiper 2 (High/Low) MISCELLANEOUS .............................................................................................................................. ................................................................. USAGE A/C CLTCH .......................................................................................................................................... ....................... Diode -- Air Conditioning, Clutch MEGA FUSE ........................................................... ......................................................................................................................................... Mega Fuse WPR .................................................................................................................................................... ....................................................... Diode -- Wiper FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse A ................................................................................................................................................. .................................................. Trailer Park Lamp Fuse B ................................................................. .......................................................................................................... Communication Interface Module Fuse C .......................................................................................................... Supplemental Inflatable Restraint System, Sensing and Diagnostic Module Fuse D ................................................ ................................................................................................................................... Trailer Auxiliary Maxi-Fuse Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1392 Fuse: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1393 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1394 Fuse Block - Underhood - Top View Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1395 Fuse Block - Underhood - Bottom View Fuse Block - Underhood X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1396 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1397 Fuse Block - Underhood X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1398 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1399 Fuse Block - Underhood X4 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1400 Fuse Block - Underhood X5 Fuse Block - Underhood X6 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1401 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1402 Fuse Block - Underhood X7 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1403 Fuse Block - Underhood X9 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1404 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1405 Fuse: Application and ID Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1406 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1407 Fuse Block - Underhood - Top View Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1408 Fuse Block - Underhood - Bottom View Fuse Block - Underhood X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1409 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1410 Fuse Block - Underhood X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1411 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1412 Fuse Block - Underhood X4 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1413 Fuse Block - Underhood X5 Fuse Block - Underhood X6 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1414 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1415 Fuse Block - Underhood X7 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1416 Fuse Block - Underhood X9 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1417 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views Fuse Block: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1422 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Battery Cable Harness Routing 1 - G104 2 - Starter 3 - Generator X2 4 - Battery 5 - G100 6 - Battery Negative Terminal 7 - Fuse Block - Underhood 8 - Ring Terminal Battery 9 - Ring Terminal Generator 10 - Battery Positive Terminal 11 - Generator Body Harness Routing 1 of 3 (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1423 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1424 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1425 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1426 Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 1 - G104 2 - Starter 3 - Battery 4 - G100 5 - Fuse Block - Underhood 6 - Battery Positive Terminal 7 - Generator Left and Right Sides of Engine Compartment Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1427 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1431 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1432 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1433 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1434 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1435 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1436 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1437 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1438 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1439 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1440 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1441 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1442 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1443 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1476 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1477 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1510 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1511 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1512 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1513 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1514 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1515 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1516 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1517 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1518 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1519 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1520 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1521 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1522 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1523 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1524 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1525 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1526 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1527 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1528 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1529 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1530 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1531 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1532 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1533 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1534 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1535 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1536 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1537 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1538 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1539 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1540 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1541 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1542 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1543 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1544 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1545 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1546 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1547 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1548 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1549 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1550 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1551 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1552 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1553 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1554 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1560 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1561 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1562 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1563 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1564 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1565 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1566 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1567 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1568 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1569 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1570 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1571 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1572 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1573 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1574 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1575 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1593 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1594 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1595 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1596 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1597 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1598 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1599 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1600 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1601 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 4. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Installation Procedure 1. Align the wiring harnesses and install the fuse relay center (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1602 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuse relay center bolts. Tighten the relay center bolts to 6 Nm (53 lb in). 3. Install the junction block cover (2). Press downward to engage the tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1608 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1609 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1610 Customer TPMS Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1611 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1612 Frequently Asked Questions Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 1619 * Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair GM Oil Life System Resetting The vehicle has a computer system that has a change engine oil message, indicating when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the kilometers or mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. The change engine oil message will come on. The oil must be changed as soon as possible. It is possible that, if the vehicle is driven under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil and filter is changed. Resetting Procedure 1. Turn the ignition to RUN with the engine OFF. 2. Press and release the reset stem in the lower center of the instrument panel (I/P) cluster until the OIL LIFE message is displayed. 3. Once the alternating OIL LIFE and RESET messages appears in the display, press and hold the reset stem until several beeps sound. This confirms the OIL LIFE system has been reset. 4. Turn the key to lock. If the CHANGE OIL message comes back on when you start the engine, the ENGINE OIL LIFE system has not reset. Repeat the procedure. Alternate Method 1. Turn the ignition key to RUN with the engine off. 2. Fully press the release the accelerator pedal 3 times within 5 seconds. Several beeps sound. This confirms the oil life system has been reset. 3. If the CHANGE/OIL message comes back on when you start the engine, the engine oil life system has not been reset. Repeat the procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1627 * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1642 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1643 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1644 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1645 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1646 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1649 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the body control module (BCM) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1650 Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement Tire Valve Stem Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1651 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1657 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1658 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1659 Customer TPMS Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1660 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1661 Frequently Asked Questions Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1674 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1675 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1676 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1677 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1678 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1681 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the body control module (BCM) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1682 Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement Tire Valve Stem Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 1683 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Spare Tire Carrier Replacement Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and use the ignition key to remove the lock. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 2. Turn the hoist shaft counterclockwise to lower the spare tire to the ground. Continue to turn the hoist shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by turning the hoist shaft clockwise until you hear two clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by turning the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, turn the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, turn the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is not visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 1688 6. Remove the spare tire hoist guide mounting bolt from the crossmember. 7. Remove the spare tire hoist shaft guide. 8. Remove the bolt. 9. Remove the hoist from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 1689 1. Install the hoist. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt and tighten to 40 Nm (30 lb ft). 3. Install the spare tire hoist shaft guide. 4. Install the mounting bolt for the guide and tighten to 30 Nm (20 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 1690 5. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 6. Turn the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1699 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1700 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1701 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1706 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1711 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1712 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1713 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1719 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1720 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1721 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1726 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1731 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1732 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1737 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1738 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1739 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1744 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1749 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1750 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1751 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1757 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1758 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1759 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1764 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1769 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1770 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1771 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Inflate the tire to the manufacturer specified pressure as stated on the tire. 4. Submerge the tire/wheel into a water bath in order to locate the leak. 5. Inscribe a mark on the wheel in order to indicate the leak areas. 6. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 7. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Important: Do not damage the exterior surface of the wheel. 8. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 9. Use general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area. 10. Apply 3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 1052366 or equivalent, to the leak area. 11. Allow for the adhesive/sealant to dry. 12. Align the inscribed mark on the tire with the valve stem on the wheel. 13. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 14. Inflate the tire to the manufacturer specified pressure as stated on the tire. 15. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 16. Balance the tire and wheel. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). 17. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 18. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 1774 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Note: * If the wheels are chrome-plated, do not re-plate or refinish the wheels. * If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: * Corrosion * Scrapes * Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Warning To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: * Lubricants * Wax * Dirt Note: * Do not re-machine the wheel. * Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Note: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Note: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: * Corrosion * Overspray * Dirt 13. Install the tire and wheel assembly to the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1778 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning ). Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/ABS Component Handling Warning). 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1779 4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled in any of the suspension components. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1780 6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly. 7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1781 Note: Perform the following service procedure with the brake rotor on a flat surface. 8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor. Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor is removed. 9. Remove the wheel bearing/hub from the brake rotor. 10. Clean the contact area between the wheel bearing/hub and the brake rotor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1782 1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from the wheel bearing/hub assembly to the brake rotor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The following service procedure is to be performed on a flat surface and to ensure that the brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT use air tools of any type for this procedure. 3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install the backing plate to the wheel bearing/hub, brake rotor assembly. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1783 6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle. Note: When performing the following service procedure, DO NOT use air tools of any type to torque the brake rotor to hub bolts. 7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1784 8. Install the brake caliper mounting bracket to the steering knuckle. 9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1785 10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake caliper mounting bracket. Note: The following service procedure is to ensure that the brake rotor is seated properly on the wheel bearing/hub assembly. 11. Tighten the mounting bolts for the brake rotor in sequence. 12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). 14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications (See: Brakes and Traction Control/Disc Brake System/Specifications/Disc Brake Component Specifications). 15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Shaft Nut .................................................................................................................................... .................................................... 260 Nm (191 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts........................................................................................................................................... .......................................................140 Nm (103 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1793 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Replacement). 4. Remove the wheel stud from the hub flange using the J 43631 . 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1796 7. Install the brake rotor. Refer to Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Replacement). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1797 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 3. Using the J 43631 , remove the wheel stud. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1798 1. Position the wheel stud in the axle flange. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1802 * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams Variable Valve Timing Solenoid: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1812 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT GEAR/SPROCKET Camshaft Sprocket Bolt First Pass....................................................................................................... ................................................................................................75 Nm (55 lb ft) Final Pass................... .............................................................................................................................................................. ..............................50 degrees Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair Camshaft: Service and Repair Camshaft Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * EN 46330 Angle Meter Removal Procedure 1. Remove the condenser. Refer to Air Conditioning Condenser Replacement (See: Heating and Air Conditioning/Condenser HVAC/Service and Repair). 2. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair). 3. Remove all of the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair). 4. Remove the camshaft sensor bolt and sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1820 5. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. 6. Remove the camshaft sprocket bolt (206). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1821 7. Remove the bolts (231) and timing chain tensioner (232). 8. Remove the camshaft sprocket and reposition the timing chain. 9. Remove the camshaft retainer bolts (204) and retainer (203). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1822 Caution: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 10. Install a bolt into the camshaft. 11. Using the bolt as a handle, carefully rotate and pull the camshaft out of the engine block. 12. Clean and inspect the camshaft and bearings. Refer to Camshaft and Bearings Cleaning and Inspection (). Installation Procedure Note: If camshaft replacement is required, the valve lifters must also be replaced. 1. Lubricate the camshaft journals and the bearings with clean engine oil. Caution: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1823 2. Using the bolt as a handle, carefully install the camshaft into the engine block. 3. Remove the bolt from the front of the camshaft. Note: Install the retainer with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. 4. Install the camshaft retainer (203) and bolts (204). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the camshaft retainer bolts. * Tighten the first design hex head bolts (3) to 25 Nm (18 lb ft). * Tighten the second design TORX(R) head bolts (4) to 15 Nm (11 lb ft). 6. Compress the timing chain tensioner guide and install the EN 46330 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1824 7. Install the timing chain tensioner (232) and bolts (231). Tighten the timing chain tensioner bolts to 25 Nm (18 lb ft). Note: * Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark (1) in the 6 o'clock position and the crankshaft sprocket (2) should be located in the 12 o'clock position. 8. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1825 9. Install the camshaft sprocket (205) and the timing chain (208). 10. Install a NEW camshaft sprocket bolt (206). 11. Tighten the camshaft sprocket bolt. 1. Tighten the camshaft sprocket bolt a first pass to 75 Nm (55 lb ft). 2. Tighten the camshaft sprocket bolt a final pass, an additional 50 degrees using the J 45059 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1826 12. Remove the EN 46330 . 13. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused. 14. Lubricate the O-ring seal with clean engine oil. 15. Install the camshaft sensor and bolt. Tighten the bolt to 25 Nm (18 lb ft). 16. Install the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair). 17. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair). 18. Install the condenser. Refer to Air Conditioning Condenser Replacement (See: Heating and Air Conditioning/Condenser HVAC/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Tools Required J 3049-A Valve Lifter Remover Removal Procedure 1. Remove the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair) or to Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair). 2. Remove the valve lifter. Refer to Valve Lifter Removal (See: Service and Repair/Overhaul). 3. Clean and inspect the valve lifters. Refer to Valve Lifter and Guide Cleaning and Inspection (See: Service and Repair/Overhaul). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 1830 1. Install the valve lifter. Refer to Valve Lifter Installation (See: Service and Repair/Overhaul). 2. Install the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair) or to Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 1834 and Repair/Overhaul). Installation Procedure Note: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 1835 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1839 and Repair/Overhaul). Installation Procedure Note: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1840 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CONNECTING ROD Connecting Rod Bearing Clearance Production................................................................................... ...................................................................................0.023-0.065 mm (0.0009-0.0025 in) Service..... .............................................................................................................................................................. ..........0.023-0.076 mm (0.0009-0.003 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING ROD Connecting Rod Bore Diameter - Bearing End................................................................................................................56.505-56.525 mm (2.224-2.225 in) Connecting Rod Bore Out-of-Round - Bearing End Production........................................................... .........................................................................................................0.004-0.008 mm (0.00015-0.0003 in) Service................................................................................................................. ........................................................0.004-0.008 mm (0.00015-0.0003 in) Connecting Rod Length - Center to Center..........................................................................................................................144.75-144.81 mm (5.69-5.70 in) Connecting Rod Bolts First Pass.......................................................................................................... .............................................................................................20 Nm (15 lb ft) Final Pass...................... .............................................................................................................................................................. ...........................85 degrees Connecting Rod Side Clearance.......................................................................................................... ..................................0.11-0.51 mm (0.00433-0.02 in) Connecting Rod Journal Diameter Production..................................................................................... .............................................................................53.318-53.338 mm (2.0991-2.0999 in) Service....... .............................................................................................................................................................. ...........................53.308 mm (2.0987 in) Connecting Rod Journal Out-of-Round Production.............. .............................................................................................................................................................. ................0.005 mm (0.0002 in) Service.............................................................................................. ......................................................................................................0.01 mm (0.0004 in) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length Production................................................... .........................................................................................................................................0.005 mm (0.0002 in) Service............................................................................................................................... ...................................................................0.02 mm (0.00078 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications CRANKSHAFT CRANKSHAFT MAIN BEARING CLEARANCE Crankshaft Main Bearing Clearance Production.................................................................................. ......................................................................................0.02-0.052 mm (0.0008-0.0021 in) Service.... .............................................................................................................................................................. ...........0.02-0.065 mm (0.0008-0.0025 in) MAIN BEARING CAP Crankshaft Bearing Cap M8 Bolts........................................................................................................ ..........................................................25 Nm (18 lb ft) Crankshaft Bearing Cap M10 Bolts First Pass in Sequence................................................................ ...................................................................................................................20 Nm (15 lb ft) Final Pass in Sequence.......................................................................................................................................... .................................................80 degrees Crankshaft Main Bearing Bore Diameter.............................................................................................. .............................69.871-69.889 mm (2.75-2.751 in) Crankshaft Main Bearing Bore Out-of-Round.. ......................................................................................................................................0.006 mm (0.0002 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Housing Replacement Special Tools * J-41476 - Front and Rear Cover Alignment Tool * J-41479-2A - Crankshaft Rear Oil Seal Installation Guide Removal Procedure 1. Remove the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Automatic Transmission Flex Plate Replacement). 2. Remove the oil pan-to-rear oil seal housing bolts (1). 3. Remove the rear oil seal housing bolts (1). 4. Remove the rear oil seal housing (2) and gasket (3). Discard the gasket. 5. Remove and discard the rear oil seal (4). Installation Procedure Note: * Do not reuse the crankshaft oil seal or rear cover gasket. * Do not apply any type of sealant to the rear cover gasket, unless specified. * The special tool in this procedure is used to properly center the crankshaft rear oil seal. * All gasket surfaces should be free of oil or other foreign material during assembly. * The crankshaft rear oil seal MUST be centered in relation to the crankshaft. * An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 1854 1. Apply a 5 mm (0.2 in) bead of sealant, 20 mm (0.8 in) to the 2 joints (a) at the rear of the block/pan. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 2. Inspect the rear oil gallery plug for proper installation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 1855 Installation Procedure - Cover with Seal 1. Install the J-41479-2A - guide cone and bolts onto the rear of the crankshaft. 2. Install the NEW rear housing gasket (1), rear housing with seal (2), rear housing-to-engine bolts (3) and oil pan-to-rear housing bolts (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the rear housing-to-engine bolts (3) until snug. Do not overtighten. 4. Tighten the oil pan-to-rear housing bolts (4) to 12 Nm (106 lb in). 5. Tighten the rear housing-to-engine bolts (3) to 30 Nm (22 lb ft). 6. Remove the J-41479-2A - guide. 7. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Automatic Transmission Flex Plate Replacement). Installation Procedure - Cover without Seal Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 1856 1. Position a NEW rear oil seal housing gasket (3) and the housing (2) to the engine. 2. Install the rear oil seal housing bolts (1) until snug. Do not overtighten. 3. Rotate the crankshaft until 2 opposing flywheel bolts holes are parallel to the oil pan surface. Note: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 4. Install the J-41476 - tool and bolts onto the rear of the crankshaft. 5. Tighten the J-41476 - tool bolts until snug. Do not overtighten. 6. Install the oil pan-to-rear oil seal housing bolts (1). 1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 lb in). 2. Tighten the rear oil seal housing-to-engine bolts to 30 Nm (22 lb ft). 7. Remove the J-41476 - tool. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 1857 8. Install a NEW crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See: Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair). 9. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Automatic Transmission Flex Plate Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications CRANKSHAFT Crankshaft Main Journal Diameter Production..................................................................................... .................................................................................64.992-65.008 mm (2.558-2.559 in) Service....... .............................................................................................................................................................. .............................64.992 mm (2.558 in) Crankshaft Main Journal Out-of-Round Production............. .............................................................................................................................................................. .............0.003 mm (0.000118 in) Service............................................................................................. .....................................................................................................0.008 mm (0.0003 in) Crankshaft Main Journal Taper Production............................................................................................................ ..................................................................................0.01 mm (0.0004 in) Service.............................. .............................................................................................................................................................. ......0.02 mm (0.00078 in) Crankshaft Rear Flange Runout.................................................................. ................................................................................................0.05 mm (0.002 in) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter.............................................................................0.7 mm (0.028 in) Crankshaft Thrust Surface Production............................................................................................................................... .........................................26.14-26.22 mm (1.029-1.0315 in) Service................................................. .................................................................................................................................................26.22 mm (1.0315 in) Crankshaft Thrust Surface Runout.............................................................................. .............................................................................0.025 mm (0.001 in) Crankshaft End Play............... ...............................................................................................................................................0.04-0.2 mm (0.0015-0.0078 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement (With LH8) (5.3L) Removal Procedure 1. Drain the cooling system/engine block. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair )Cooling System Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the coolant heater cord electrical connector. Note: Do not score the surface of the engine block hole when removing the coolant heater. 4. Remove the coolant heater from the engine block. 5. Remove any burrs, sealer, or other rough spots. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 1865 Installation Procedure 1. If reusing the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the coolant heater to the engine block. Tighten the coolant heater to 50 Nm (37 lb ft). 3. Connect the coolant heater cord electrical connector. 4. Lower the vehicle. 5. Fill the cooling system/engine block. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair )Cooling System Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 1866 Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement (With LH8) (5.3L) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the coolant heater cord electrical connector. 3. Remove the coolant heater cord clip from the engine harness channel. 4. Remove the coolant heater cord clip from the power steering gear outlet hose. 5. Lower the vehicle. 6. Remove the coolant heater cord bolt from the frame. 7. Remove the coolant heater cord from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 1867 1. Install the coolant heater cord to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the coolant heater cord clip to the frame and install the coolant heater cord bolt. Tighten the bolt to 8 Nm (71 lb in). 3. Raise the vehicle. 4. Install the coolant heater cord clip to the power steering gear outlet hose. 5. Install the coolant heater cord clip to the engine harness channel. 6. Connect the coolant heater cord electrical connector. 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications CRANKSHAFT PULLEY Crankshaft Balancer Bolt First Pass..................................................................................................... ..............................................................................................150 Nm (111 lb ft) Second Pass............. .............................................................................................................................................................. ................. Loosen 360 degrees Third Pass......................................................................................... ............................................................................................................50 Nm (37 lb ft) Final Pass....... .............................................................................................................................................................. ........................................230 degrees Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1871 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Special Tools * J 41478 Crankshaft Front Oil Seal Installer * J 41665 Crankshaft Balancer and Sprocket Installer * J 41816-A Crankshaft Balancer Remover * J 41816-2 Crankshaft End Protector * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the air conditioning (A/C) drive belt. Refer to Air Conditioning Compressor Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement). 2. Remove the cooling fan and shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV, LLR) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Shroud Replacement (LH8) (See: Cooling System/Fan Shroud/Service and Repair). 3. Remove the starter motor. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. 4. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1872 5. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt at this time. The old balancer bolt will be used during the balancer installation procedure. 6. Install the J 41816 (1) and J 41816-2 (2) to the crankshaft balancer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1873 Note: The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. 7. Use the J 41816 and the J 41816-2 to remove the crankshaft balancer (138). 8. Remove the J 41816 and the J 41816-2 from the crankshaft balancer. Installation Procedure Note: * The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and fourth passes tighten the NEW bolt to the proper torque. * The used crankshaft balancer bolt will be used ONLY during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and fourth passes of the balancer bolt tightening procedure. Note: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation. 1. Position the crankshaft balancer (138) onto the end of the crankshaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1874 2. Install the J 41665 and the threaded rod from the J 41478 to crankshaft balancer and install the balancer. 1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the J 41665 and the threaded rod. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the USED crankshaft balancer bolt (139). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1875 Tighten the USED bolt to 330 Nm (240 lb ft). 4. Remove the USED crankshaft balancer bolt. Note: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the balancer bore. 5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimension, install the J 41665 and repeat the installation procedure. 6. Install the NEW crankshaft balancer bolt (139). 1. Tighten the bolt a first pass to 50 Nm (37 lb ft). 2. Tighten the bolt a final pass to 140 degrees using J 45059 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1876 7. Remove the J 42386-A (1) and bolts. 8. Install the starter motor. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 9. Install the cooling fan and shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV, LLR) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Shroud Replacement (LH8) (See: Cooling System/Fan Shroud/Service and Repair). 10. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement). 11. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Powertrain Management/Computers and Control Systems/Crankshaft Position Sensor/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications PISTON CLEARANCE Piston-to-Bore Clearance Production................................................................................................... ....................................................-0.036 to +0.016 mm (-0.0014 to +0.0006 in) Service Limit with Skirt Coating Worn Off..........................................................................................................................................0.071 mm (0.0028 in) PISTON DIAMETER Piston Diameter - Measured Over Skirt Coating..........................................................................................................96.002-96.036 mm (3.7796-3.7809 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTON RING END GAP Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore Production................... ...........................................................................................................................................................0. 23-0.44 mm (0.009-0.017 in) Service................................................................................................... ................................................................................0.23-0.5 mm (0.009-0.0196 in) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore Production......................................... .......................................................................................................................................0.44-0.7 mm (0.017-0.027 in) Service....................................................................................................................... ............................................................0.44-0.76 mm (0.0173-0.03 in) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore Production.......................................................................... ....................................................................................................0.18-0.75 mm (0.007-0.029 in) Servi ce.......................................................................................................................................................... .........................0.18-0.81 mm (0.007-0.032 in) PISTON RING TO GROOVE CLEARANCE Piston Ring-to-Groove Clearance - First Compression Ring Production.................................................................................................................................... ................................0.04-0.085 mm (0.00157-0.00335 in) Service...................................................... ...................................................................................................................0.04-0.085 mm (0.00157-0.00335 in) Piston Ring-to-Groove Clearance - Second Compression Ring Production...... .............................................................................................................................................................. ..0.04-0.078 mm (0.00157-0.0031 in) Service...................................................................................... .....................................................................................0.04-0.078 mm (0.00157-0.0031 in) Piston Ring-to-Groove Clearance - Oil Control Ring Production..................................................................... .....................................................................................................0.012-0.2 mm (0.0005-0.0078 in) S ervice.................................................................................................................................................... ...........................0.012-0.2 mm (0.0005-0.0078 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1888 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1889 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1890 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 1891 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1895 and Repair/Overhaul). Installation Procedure Note: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1896 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side Valve Rocker Arm Cover Replacement - Left Side Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the engine harness electrical connector (1) from the ignition coil wire harness. 4. Remove the engine harness clip (4) from the ignition coil bracket stud. 5. Reposition the engine harness, as necessary. 6. Remove the spark plug wires (724) from the ignition coils. * Twist each plug wire 1/2 turn. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1901 * Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the ignition coil bracket studs (720). 8. Remove the ignition coil bracket (719). 9. Remove the positive crankcase ventilation (PCV) hose. 10. Loosen the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1902 12. Remove and discard the old gasket (1). Installation Procedure Note: * All gasket surfaces should be free of oil an/or other foreign material during assembly. * DO NOT reuse the valve rocker arm cover gasket. * If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly. 1. Install a NEW rocker cover gasket (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1903 2. Install the valve rocker arm cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the rocker arm cover bolts. Tighten the bolts to 12 Nm (106 lb in). 4. Install the PCV hose. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1904 5. Apply threadlock to the threads of the ignition coil bracket studs. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 6. Position the ignition coil bracket (719) onto the rocker cover. 7. Install the ignition coil bracket studs (720). Tighten the studs to 12 Nm (106 lb in). 8. Install the spark plug wires (724) to the ignition coils. 9. Position the engine harness, as necessary. 10. Install the engine harness clip (4) to the ignition coil bracket stud. 11. Connect the engine harness electrical connector (1) to the ignition coil wire harness. 12. Install the CPA retainer (2). 13. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1905 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side Valve Rocker Arm Cover Replacement - Right Side Removal Procedure 1. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). 2. Remove the connector position assurance (CPA) lock. 3. Disconnect the main electrical connector (1) to the ignition coil wire harness. 4. Remove the harness clips. 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. * Twist each plug wire 1/2 turn. * Pull only on the boot in order to remove the wire from the ignition coil. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1906 7. Remove the heater hose bracket bolt (1) from the front of the right cylinder head. 8. If necessary, remove the ignition coil bracket studs from the rocker arm cover. 9. If necessary, remove the ignition coils and bracket from the rocker cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1907 10. Remove the vent hose (2) from the valve rocker arm cover (1). 11. Remove the valve rocker arm cover bolts. 12. Remove the valve rocker arm cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1908 13. Remove the gasket (1) from the rocker cover. 14. Discard the OLD gasket. 15. Remove the oil fill cap from the oil fill tube. 16. Remove the oil fill tube from the rocker cover, if required. 17. Discard the oil fill tube. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1909 Note: * All gasket surfaces should be free of oil or other foreign material during assembly. * DO NOT reuse the valve rocker arm cover gasket. * The valve rocker arm cover bolt grommets may be reused. * If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. 1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position. 3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position. 4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1910 5. Install the valve rocker arm cover onto the cylinder head. 6. Install new rocker arm cover grommets, if necessary. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the rocker arm cover bolts and grommets and tighten the bolts to 12 Nm (106 lb in). 8. Install the vent hose (2) to the valve rocker arm cover (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1911 9. Apply threadlock to the threads of the bracket bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 10. If necessary, install the ignition coils and bracket to the rocker arm cover. 11. If necessary, install the ignition coil bracket studs to the rocker cover. Tighten the studs to 12 Nm (106 lb in). 12. Install the heater hose bracket bolt (1) to the front of the right cylinder head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 1912 13. Install the spark plug wires to the ignition coils. 14. Position the engine harness, if necessary. 15. Install the harness clips. 16. Connect the main electrical connector (1) feeding the ignition coils. 17. Install the CPA lock. 18. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions Valve Spring: Service Precautions Valve Springs Can Be Tightly Compressed Warning Warning Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 1916 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair). 2. Disconnect the spark plug wire at the spark plug. * Twist each plug wire boot 1/2 turn. * Pull only on the boot in order to remove the wire from the spark plug. Note: Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 1917 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15. Remove the valve stem oil seal (222). 16. Remove the valve (228). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 1918 1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224). 7. Compress the valve spring using the J 38606 . 8. Install the valve keys. * Use grease in order to hold the valve keys in place. * Make sure the keys seat properly in the groove of the valve stem. * Carefully release the valve spring pressure, making sure the valve keys stay in place. * Remove the J 38606 . * Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 1919 9. Remove the J 22794 from the spark plug port. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 lb ft). 11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug. 13. Inspect the wires for proper installation: * Push sideways on each boot in order to check for proper installation. * Reinstall any loose boot. 14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1925 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1926 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1927 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1928 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump - The generator - The A/C compressor - The engine cooling fan - The water pump, if belt driven The drive belt system may use 2 belts. The drive belt (1) is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plies containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system has an idler pulley, which is used to add wrap to the adjacent pulleys. A/C Compressor Drive Belt Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1929 The outward appearance of the belt (1) is similar to the current design serpentine belt. The reinforcing cord provides its unique qualities. The belt cord is made of a polyamid material. The polyamid cord is more elastic than the more traditional aramid or polyester cord designs. A tensioner is not needed. Polyamid cord, when combined with a more elastic backing compound, ensures the belt is able to maintain the specified tension within the specified range of usage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1932 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1933 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1934 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1935 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1936 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1937 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1938 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory Removal Procedure 1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1941 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Start the vehicle and inspect the drive belt for proper operation. 10. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1942 Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement Air Conditioning Compressor Belt Replacement Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). 2. Remove the cooling fan. Refer to Fan Replacement (LH8) (See: Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (LLV, LLR) (See: Cooling System/Radiator Cooling Fan/Service and Repair). 3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys. Installation Procedure 1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install the belt installation tool (3) onto the balancer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1943 3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4. Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light tension to the belt. 5. Position the lower portion of the belt (1) with the ribbed area facing forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1944 6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull the belt (2) forward. Ensure that the ribbed area of the belt remains facing forward and the belt aligns properly to the A/C pulley. 7. Inspect the drive belt (1) for proper installation and alignment. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 1945 8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install the cooling fan. Refer to Fan Replacement (LH8) (See: Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (LLV, LLR) (See: Cooling System/Radiator Cooling Fan/Service and Repair). 10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1949 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Accessory Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory). 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Position the drive belt tensioner to the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1950 2. Install and tighten the drive belt tensioner bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Caution: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. Visual/Physical Inspection 1. Support the powertrain using the appropriate support method; refer to the powertrain mount replacement procedure. Raising the powertrain removes the weight from the engine mount and creates slight tension in the rubber. 2. Clean the mount and surrounding area to ensure good visibility of the mount condition. 3. Verify all attaching fasteners are present and at the correct torque. Refer to Engine Mount Replacement Left Side (See: Service and Repair) and/or Engine Mount Replacement - Right Side (See: Service and Repair) for any torque sequencing and/or torque specifications. Note: Observe the engine mount while raising the engine. If the engine mount exhibits any of the following conditions the mount may require replacement. Refer to Engine Mount Replacement Left Side (See: Service and Repair) and/or Engine Mount Replacement - Right Side (See: Service and Repair). 4. Slightly raise the engine approximately 5-7 mm. 5. Inspect the mount for any of the following conditions: * Hard rubber surfaces - covered with extreme heat check cracks. * Rubber separation from the metal plate of the engine mount. * Rubber is split through the center of the engine mount. Note: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is from the engine mount , and not the engine or an external source. * If equipped with a hydraulic mount, inspect for GLYCOL(TM) fluid leaking from the engine mount. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement - Left Side Removal Procedure Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Remove the front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 2. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (LH8) (See: Exhaust System/Exhaust Manifold/Service and Repair/Exhaust Manifold Replacement - Left Side). 3. Remove the engine mount to frame bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1956 Note: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. 4. Place an adjustable (screw type) jack to the tab (1) located on the engine block. 5. Working through the wheelhouse opening, remove the engine mount to engine bolts (1). 6. Using the adjustable jack, raise the engine slightly until there is enough clearance to remove the engine mount. 7. Remove the engine mount. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1957 1. Position the engine mount to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Working through the wheelhouse opening, install the engine mount to engine nuts (1) and tighten to 55 Nm (41 lb ft). 3. Using the adjustable jack, lower the engine until the engine mount is sitting flush on the frame. 4. Remove the adjustable jack from the engine block. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1958 5. Install the engine mount to frame bolts (1) and tighten to 65 Nm (48 lb ft) starting with the middle bolt then either side bolt. 6. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (LH8) (See: Exhaust System/Exhaust Manifold/Service and Repair/Exhaust Manifold Replacement - Left Side). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1959 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Side Removal Procedure Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Remove the front tire and wheels. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 2. Remove the right side exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (LH8) (See: Exhaust System/Exhaust Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side). 3. Unbolt the air conditioning compressor and position aside. Refer to Air Conditioning Compressor Replacement (LH8) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair)Air Conditioning Compressor Replacement (LLV, LLR) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair). 4. Remove the air conditioning bracket bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1960 5. Remove the engine mount to frame bolts (1). Note: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. 6. Place an adjustable (screw type) jack to the tab (1) located on the engine block. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1961 7. Remove the engine mount to engine bolts (1). 8. Using the adjustable jack, raise the engine slightly until there is enough clearance to remove the engine mount. 9. Remove the engine mount (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1962 1. Position the engine mount (1) to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the engine mount to engine nuts (1) and tighten to 55 Nm (41 lb ft). 3. Using the adjustable jack, lower the engine until the engine mount is sitting flush on the frame. 4. Remove the adjustable jack from the engine block. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 1963 5. Install the air conditioning compressor bracket bolts (1). 6. Install the air conditioning compressor. Refer to Air Conditioning Compressor Replacement (LH8) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair)Air Conditioning Compressor Replacement (LLV, LLR) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair). 7. Install the engine mount to frame bolts (1) and tighten to 65 Nm (48 lb ft) starting with the middle bolt then either side bolt. 8. Install the right side exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (LH8) (See: Exhaust System/Exhaust Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side). 9. Install the front tire and wheels. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 10. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 2. Loosen the drive belt idler pulley bolt and remove the idler pulley. Installation Procedure 1. Position the drive belt idler pulley to the generator bracket and tighten the idler pulley bolt finger tight. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the drive belt idler pulley bolt. Tighten the bolt to 50 Nm (37 lb ft). 3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE Oil Pressure - Minimum - Hot..................................................................................................41 kPa at 1,000 engine RPM (124 kPa at 2,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................165 kPa at 4,000 engine RPM (6 psig at 1,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................18 psig at 2,000 engine RPM (24 psig at 4,000 engine RPM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1971 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required * EN-47971 Oil Pressure Gage Adapter * J 21867 Pressure Gage 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: * Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil). * Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal 6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications). 10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul). * Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation (See: Service and Repair/Overhaul). * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump pressure relief valve * Excessive bearing clearance * Cracked, porous, or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See: Service and Repair/Overhaul). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the cylinder number 2 spark plug and wire. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 2. Remove the oil level indicator from the tube. 3. Remove the oil level indicator tube bolt. 4. Remove the oil level indicator tube from the engine block. Note: The O-ring seal may be reused if not cut or damaged. 5. Inspect the O-ring seal for cuts or damage. 6. Remove the O-ring seal from the tube, if required. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 1975 1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal onto the oil level indicator tube. 3. Install the oil level indicator tube behind the exhaust manifold. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Install the oil level indicator tube into the block. Install the tube with the collar flush to the block. 6. Lower the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the oil level indicator tube bolt. Tighten the bolt to 25 Nm (18 lb ft). 8. Install the oil level indicator to the tube. 9. Install the cylinder number 2 spark plug and wire. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1980 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1981 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1984 Engine Oil: Fluid Type Specifications ENGINE OIL Look for three things: 1. Use only an oil that meets GM Standard GM6094M. 2. Temperatures above -20°F (-29°C), SAE 5W-30 is best for the vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50 or any other viscosity grade oil not recommended. 3. American Petroleum Institute (API) starburst symbol Oils meeting these requirements should have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Notice: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by the vehicle warranty. COLD TEMPERATURE OPERATION If in an area of extreme cold, where the temperature falls below -20°F (-29°C), use either an SAE 5W-30 synthetic oil or an SAE 0W-30 engine oil. Both provide easier cold starting for the engine at extremely low temperatures. Always use an oil that meets the required specification, GM6094M. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to the oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is needed for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1985 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1986 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter. Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1987 Tighten the drain plug to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1992 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1993 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter. Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1994 Tighten the drain plug to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a suitable drain pan under the oil filter. 3. Remove the oil filter (437). 4. Remove the oil filter adapter (438). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 1998 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the oil filter adapter (438). Tighten the adapter to 55 Nm (40 lb ft). 2. Lubricate the oil filter seal with clean engine oil. 3. Install the oil filter (437). Tighten the filter to 30 Nm (22 lb ft). 4. Lower the vehicle. 5. Refill the engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and/or Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 6. Start the engine and inspect for leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications OIL PAN Oil Pan M6 Bolts - Oil Pan-to-Rear Housing........................................................................................ .......................................................12 Nm (106 lb in) Oil Pan M8 Bolts - Oil Pan-to-Engine Block and Oil Pan-to-Front Cover.....................................................................................................25 Nm (18 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2002 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 2. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement (See: Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). 3. Remove the front differential, if equipped. Refer to Differential Carrier Assembly Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Carrier/Service and Repair). 4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and Repair). 5. Remove the transmission oil cooler lines (1) from the retainer (2). 6. Remove the transmission oil cooler line retaining bracket bolt (3) and bracket (4). 7. Remove the inner axle shaft. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement). 8. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 9. Remove the flywheel inspection cover from the left side of the transmission. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2003 10. Remove the battery cable channel bolt from the front of the oil pan. 11. Remove the battery cable channel from the oil pan. 12. Loosen the 2 upper air conditioning (A/C) compressor bracket bolts (4). 13. Remove the 2 lower A/C compressor bracket bolts (3). Position the A/C compressor aside and secure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2004 14. Remove the 2 lower bellhousing bolts (1). 15. Remove the oil pan bolts (1). 16. Remove the oil pan by tilting the rear of the oil pan down to clear the transmission, pull the oil pan rearward past the front wire harness, then lower the oil pan clear of the vehicle. Note: * The oil pan gasket is reusable. It is NOT necessary to remove the oil pan gasket unless damaged. * DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2005 17. Drill out the oil pan gasket retaining rivets (2), if required. 18. Remove the gasket (1) from the pan. 19. Discard the gasket and rivets. 20. Clean and inspect the oil pan. Refer to Automatic Transmission Flex Plate Cleaning and Inspection (). Installation Procedure Note: * The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. * If replacing the oil pan gasket it is not necessary to rivet the NEW gasket to the oil pan. 1. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. 2. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2006 3. Pre-assemble the oil pan gasket and bolts (1) to the pan. * Install the gasket onto the pan. * Install the oil pan bolts to the pan and through the gasket. 4. Install the oil pan, oil pan gasket, and bolts to the engine block as an assembly. 5. Hand thread the oil pan bolts into the engine block until snug. Do not tighten at this time. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the 2 lower bellhousing bolts (1). * Tighten the lower bellhousing bolts to 50 Nm (37 lb ft). * Tighten the 2 rear oil pan to rear cover bolts to 12 Nm (106 lb in). * Tighten the remaining oil pan bolts to 25 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2007 7. Install the 2 lower A/C compressor bracket bolts (3) and tighten to 50 Nm (37 lb ft). 8. Tighten the 2 upper A/C compressor bracket bolts (4) to 50 Nm (37 lb ft). 9. Install the battery cable channel to the oil pan. 10. Install the battery cable channel bolt to the oil pan and tighten the bolt to 12 Nm (106 lb in). 11. Install the flywheel inspection cover to the left side of the transmission. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2008 12. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 13. Install the inner axle shaft. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement). 14. Install the transmission oil cooler line retaining bracket (4) and bolt (3) and tighten to 9 Nm (80 lb in). 15. Install the transmission oil cooler lines (1) to the retainer (2). 16. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement (See: Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). 17. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and Repair). 18. Install the front differential, if equipped. Refer to Differential Carrier Assembly Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Carrier/Service and Repair). 19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2012 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Page 2016 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Page 2017 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE Oil Pressure - Minimum - Hot..................................................................................................41 kPa at 1,000 engine RPM (124 kPa at 2,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................165 kPa at 4,000 engine RPM (6 psig at 1,000 engine RPM) Oil Pressure - Minimum Hot...................................................................................................18 psig at 2,000 engine RPM (24 psig at 4,000 engine RPM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2022 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required * EN-47971 Oil Pressure Gage Adapter * J 21867 Pressure Gage 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: * Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil). * Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal 6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications). 10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul). * Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation (See: Service and Repair/Overhaul). * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump pressure relief valve * Excessive bearing clearance * Cracked, porous, or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See: Service and Repair/Overhaul). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2027 Intake Manifold: Specifications INTAKE MANIFOLD Intake Manifold Bolts First Pass in Sequence...................................................................................... ..............................................................................................5 Nm (44 lb in) Final Pass in Sequence. .............................................................................................................................................................. ..................10 Nm (89 lb in) THROTTLE BODY Throttle Body Bolts............................................................................................................................... .........................................................10 Nm (89 lb in) Throttle Body Nuts............................................ .............................................................................................................................................10 Nm (89 lb in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement Intake Manifold: Service and Repair Intake Manifold Replacement Intake Manifold Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 3. Remove the engine harness retainer nut (1). 4. Remove the engine harness retainer from the stud and locator pin. 5. Disconnect the engine harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid. 6. Disconnect the engine wiring harness electrical connector (3) from the manifold absolute pressure (MAP) sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2030 7. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector. 8. Disconnect the engine harness electrical connectors (2) from the left side fuel injectors. 9. Remove the engine harness clip (3) from the ignition coil bracket stud. 10. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector. 11. Disconnect the engine harness electrical connector (2) from the throttle actuator. 12. Remove the engine harness clip (3) from the ignition coil bracket stud. 13. Disconnect the engine harness electrical connectors (4) from the right side fuel injectors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2031 14. Remove the engine harness clips (1). 15. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor. 16. Gather the engine harness branches and tie the harness up out of the way to the front of the engine compartment. 17. Disconnect the engine oil pressure sensor electrical connector (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2032 18. Reposition the brake booster vacuum hose clamp at the booster. 19. Remove the brake booster vacuum hose from the booster fitting. 20. Secure the brake booster vacuum hose to the intake manifold. 21. Disconnect the EVAP canister purge tube (1) quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 22. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2033 23. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting. 24. Position the hose out of the way. 25. Loosen the intake manifold bolts (512). Note: The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 26. Remove the intake manifold (500). 27. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2034 28. Remove and discard the intake manifold gaskets (514). 29. If replacing the intake manifold, perform the following steps, otherwise proceed to step 21 of the installation procedure. 30. Place the intake manifold on a clean work surface. 31. Reposition the brake booster vacuum hose clamp at the intake manifold. 32. Remove the brake booster vacuum hose from the intake manifold nipple. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2035 33. Remove the upper intake manifold cover nut. 34. Remove the upper intake manifold cover. 35. Remove the manifold absolute pressure (MAP) sensor retainer. 36. Remove the MAP sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2036 37. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 38. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 39. Remove the EVAP tube and purge solenoid. 40. Remove the throttle body bolts/nuts. 41. Remove the throttle body. 42. Remove and discard the throttle body gasket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2037 43. Remove the fuel rail bolts. Note: Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 44. Remove the fuel rail. 45. Remove and discard the fuel injector lower O-ring seals. Note: Evenly push in the RED collar in order to remove the nipple. 46. Remove the brake booster vacuum hose nipple. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2038 1. If the intake manifold was replaced perform the following steps, otherwise proceed to step 21. Note: Evenly push in the RED collar in order to install the nipple. 2. Install the brake booster vacuum hose nipple to the NEW intake manifold. 3. Install NEW fuel injector lower O-ring seals onto the injectors. 4. Lubricate the NEW O-ring seals with clean engine oil. Note: Push down firmly on both sides of the rail until all the injectors have been seated into their bores. 5. Install the fuel rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the fuel rail bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2039 Tighten the bolts to 10 Nm (89 lb in). 7. Install a NEW throttle body gasket to the intake manifold. 8. Install the throttle body. 9. Install the throttle body bolts/nuts. Tighten the bolts/nuts to 10 Nm (89 lb in). 10. Install the EVAP tube and purge solenoid. 11. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2040 13. Lubricate the MAP sensor seal with clean engine oil. 14. Install the MAP sensor. 15. Install the MAP sensor retainer. 16. Install the upper intake manifold cover. 17. Install the upper intake manifold cover nut until snug Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2041 18. Install the brake booster vacuum hose to the intake manifold nipple. 19. Position the brake booster vacuum hose clamp at the intake manifold. 20. Secure the brake booster vacuum hose to the intake manifold. 21. Install NEW intake manifold gaskets (514) to the intake manifold. 22. Remove the covers from the cylinder head passages. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2042 23. Install the intake manifold (500). Note: The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 24. Tighten the intake manifold bolts (512) until snug. 25. Tighten the intake manifold bolts to specifications. * Tighten the bolts a first pass in the sequence shown to 5 Nm (44 lb in). * Tighten the bolts a final pass in the sequence shown to 10 Nm (89 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2043 26. Position and install the PCV hose to the intake manifold fitting. 27. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 28. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2044 29. Unsecure the brake booster vacuum hose from the intake manifold. 30. Install the brake booster vacuum hose to the booster fitting. 31. Position the brake booster vacuum hose clamp at the booster. 32. Connect the engine oil pressure sensor electrical connector (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2045 33. Untie the engine harness branches from the front of the engine compartment and position over the engine. 34. Connect the engine harness electrical connector (2) to the ECT sensor. 35. Position the engine harness clips (1) to the bracket. 36. Connect the engine harness electrical connectors (4) to the right side fuel injectors. 37. Install the engine harness clip (3) to the ignition coil bracket stud. 38. Connect the engine harness electrical connector (2) to the throttle actuator. 39. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2046 40. Install the engine harness clip (3) to the ignition coil bracket stud. 41. Connect the engine harness electrical connectors (2) to the left side fuel injectors. 42. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector. 43. Install the CPA retainer (1). 44. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 45. Connect the engine harness electrical connector (2) to the EVAP canister purge solenoid. 46. Install the engine harness retainer to the stud and locator pin. 47. Install the engine harness retainer nut (1). Tighten the nut to 5 Nm (44 lb in). 48. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 49. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2047 Intake Manifold: Service and Repair Upper Intake Manifold Sight Shield Replacement Upper Intake Manifold Sight Shield Replacement Removal Procedure 1. Remove the oil fill cap. 2. Grasp the front of the intake manifold sight shield and lift up disengaging the grommets from the studs. 3. Remove the intake manifold sight shield from the retainer slots. 4. Remove the intake manifold sight shield retainer bolts and retainer, if required. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 2048 1. Position the intake manifold sight shield on top of the intake manifold, aligning the holes, if required. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the intake manifold sight shield retainer bolts, if required. Tighten the bolts to 5 Nm (44 lb in). 3. Install the intake manifold sight shield tabs into the slots in the retainer. 4. Align the intake manifold sight shield grommets with the studs. 5. Gently push down on the intake manifold sight shield over the grommets, seating the intake manifold sight shield. 6. Install the oil fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement Tools Required J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the automatic transmission flexplate, refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Automatic Transmission Flex Plate Replacement). 2. Remove and discard the crankshaft rear oil seal (141). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2053 Important: For proper orientation, note the installation direction of the oil seal. The oil seal is a reverse-lip design. The part number is applied to the outside face of the seal, as shown. 1. Inspect the seal and identify the part number markings for proper orientation. 2. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft. 3. Tighten the bolts until snug. Do not overtighten. 4. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear seal bore. Install the oil seal with the part number markings facing away from the engine. 5. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. 6. Align the oil seal into the tool (1). 7. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore. 8. Remove the J 41479 . 9. Install the automatic transmission flexplate, refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Automatic Transmission Flex Plate Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Special Tools J 41478 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 2. Remove the crankshaft front oil seal (1) from the front cover. Installation Procedure Important: * Do not lubricate the oil seal sealing surface. * Do not reuse the crankshaft front oil seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2057 1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. 3. Install the crankshaft front oil seal (1) onto the J 41478 guide. 4. Install the J 41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J 41478 in order to install the oil seal into the cover bore. 1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. 3. Remove the J 41478 . 4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. 6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair). 2. Disconnect the spark plug wire at the spark plug. * Twist each plug wire boot 1/2 turn. * Pull only on the boot in order to remove the wire from the spark plug. Note: Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2061 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15. Remove the valve stem oil seal (222). 16. Remove the valve (228). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2062 1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224). 7. Compress the valve spring using the J 38606 . 8. Install the valve keys. * Use grease in order to hold the valve keys in place. * Make sure the keys seat properly in the groove of the valve stem. * Carefully release the valve spring pressure, making sure the valve keys stay in place. * Remove the J 38606 . * Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2063 9. Remove the J 22794 from the spark plug port. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 lb ft). 11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug. 13. Inspect the wires for proper installation: * Push sideways on each boot in order to check for proper installation. * Reinstall any loose boot. 14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2068 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 2072 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 2073 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT GEAR/SPROCKET Camshaft Sprocket Bolt First Pass....................................................................................................... ................................................................................................75 Nm (55 lb ft) Final Pass................... .............................................................................................................................................................. ..............................50 degrees Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Camshaft Timing Chain and Sprocket Replacement Special Tools * J 8433-1 Puller Bar * J 41478 Crankshaft Front Oil Seal Installer * J 41558 Crankshaft Sprocket Remover * J 41665 Crankshaft Balancer and Sprocket Installer * J 41816-2 Crankshaft End Protector Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair). Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 3. Remove and discard the camshaft sprocket bolt (206). 4. Remove the camshaft sprocket (205) and timing chain (208). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2081 5. Remove the bolts (231) and timing chain tensioner (232). 6. Use the J 41816-2 (1), the J 41558 (2), bolts (3), and the J 8433 (4) in order to remove the crankshaft sprocket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2082 7. Remove the crankshaft sprocket (207). 8. Remove the crankshaft sprocket key, as required. Installation Procedure 1. Install the key into the crankshaft keyway, if previously removed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2083 2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft. 3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2084 4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. 6. Compress the timing chain tensioner guide and install the EN 46330 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2085 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the timing chain tensioner (232) and bolts (231). Tighten the timing chain tensioner bolts to 25 Nm (18 lb ft). Note: * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. 8. Install the camshaft sprocket (205), timing chain (208), and bolt (206). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2086 9. Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 10. Remove the EN 46330 . Note: Do not apply threadlock to the flex plate bolts at this time. 11. Temporarily install the automatic transmission flex plate and bolts. Refer to Automatic Transmission Flex Plate Cleaning and Inspection (). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2087 12. Install the J 42386-A and bolts. Use 1 M10-1.5 x 120 mm bolt and 1 M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). 13. Tighten the camshaft sprocket bolt. 1. Tighten the camshaft sprocket bolt a first pass to 75 Nm (55 lb ft). 2. Tighten the camshaft sprocket bolt a final pass an additional 50 degrees using the J 45059 . 14. Remove the J 42386-A and bolts. 15. Remove the automatic transmission flex plate and bolts. Refer to Automatic Transmission Flex Plate Removal (). 16. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolt................................................................................................................ ..........................................................25 Nm (18 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover (TIMING COVER) Front Cover Bolts.................................................................................................................................. ..........................................................25 Nm (18 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2097 Timing Cover: Service and Repair Engine Front Cover Replacement Special Tools * J 41476 Front and Rear Cover Alignment Tool * J 41480 Front and Rear Cover Alignment Removal Procedure 1. Remove the water pump. Refer to Water Pump Replacement (With LH8) (See: Water Pump/Service and Repair)Water Pump Replacement (LLV, LLR) (See: Water Pump/Service and Repair). 2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 3. Disconnect the engine harness electrical connector (1) from the camshaft position (CMP) sensor wire harness electrical connector. 4. Remove the oil pan-to-front cover bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2098 5. Remove the front cover bolts (1). 6. Remove the front cover (2) and gasket (3). 7. Discard the front cover gasket. 8. Remove the crankshaft front oil seal. 9. If replacing the engine front cover perform the following steps, otherwise proceed to step 10 of the installation procedure. 10. Remove the CMP sensor wire harness bolts (1, 6). 11. Disconnect the CMP sensor wire harness from the CMP sensor. 12. Remove the CMP sensor wire harness (5). 13. Remove the CMP sensor (2). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2099 Note: * Do not use the crankshaft oil seal or the engine front cover gasket again. * Do not apply any type of sealant to the front cover gasket, unless specified. * The special tools in this procedure are used to properly align the engine front cover at the oil pan surface and to center the crankshaft front oil seal. - All gasket surfaces should be free of oil or other foreign material during assembly. The crankshaft front oil seal MUST be centered in relation to the crankshaft. - The oil pan sealing surface at the front cover and engine block MUST be aligned within specifications. - An improperly aligned front cover may cause premature front oil seal wear and/or engine assembly oil leaks. 1. Install the front cover gasket (3), front cover (2), and bolts (1). 2. Tighten the cover bolts finger tight. Do not overtighten. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Start the tool-to-front cover bolts. Do not tighten the bolts at this time. 3. Install the J 41480 . Tighten the tool-to-engine block bolts to 25 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2100 Note: Align the tapered legs of the tool with the machined alignment surfaces on the front cover. 4. Install the J 41476 . 5. Install the crankshaft balancer bolt. 1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. 2. Tighten the J 41480 . 3. Tighten the engine front cover bolts to 25 Nm (18 lb ft). 6. Remove the tools. 7. Measure the oil pan surface flatness, front cover-to-engine block. 1. Place a straight edge across the engine block and front cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. 2. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface or no greater than 0.5 mm (0.02 in) (a) below flush. 8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure. 9. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2101 10. Inspect the camshaft position (CMP) sensor O-ring seal (3) for cuts or damage. If the seal is not cut or damaged, it may be used again. 11. Lubricate the O-ring seal with clean engine oil. 12. Install the O-ring seal onto the sensor (2). 13. Install the sensor to the cover. 14. Install the CMP sensor wire harness (5) and bolts (1, 6). Tighten the bolts to 12 Nm (106 lb in). 15. Connect the engine harness electrical connector (1) to the CMP sensor wire harness electrical connector. 16. Install a NEW crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement (See: Seals and Gaskets/Front Crankshaft Seal/Service and Repair). 17. Install the water pump. Refer to Water Pump Replacement (With LH8) (See: Water Pump/Service and Repair)Water Pump Replacement (LLV, LLR) (See: Water Pump/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams Variable Valve Timing Solenoid: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure (Ignition ON, engine OFF)............................................................................................. ..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than 34 kPa (5 psi) in 1 minute Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2110 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2111 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Fuel Pressure Gage * J 37287 - Fuel Line Shut-Off Adapters Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal). 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2112 ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gage. The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test normal, replace the fuel sender. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Return Line/Service and Repair) * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2117 4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6. Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing. Installation Procedure 1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to engage the duct to the ball stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the air cleaner outlet duct clamp (1) at the throttle body. Tighten the clamp to 3.5 Nm (31 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2118 4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing. Tighten the clamp to 3.5 Nm (31 lb in). 5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Release the air cleaner upper housing retainer clips (1). 3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2122 1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper housing (1). 3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2128 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2129 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2130 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2131 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2138 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. * Twist each spark plug 1/2 turn. * Pull only on the boot in order to remove the wire from each spark plug. 2. Remove the spark plug wire from the ignition coil. * Twist each spark plug boot 1/2 turn. * Pull only on the boot in order to remove the wires from the ignition coil. Installation Procedure 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the wires for proper installation: * Push sideways on each boot in order to inspect the seating. * Reinstall any loose boot. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2147 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2148 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2154 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2155 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2156 Spark Plug: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2157 Spark Plug: Application and ID Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2158 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1) - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3,4). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2159 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A looses center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2160 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the spark plug. Tighten the plug to 20 Nm (15 lb ft). 5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2164 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP Water Pump Bolts First Pass................................................................................................................ .......................................................................................15 Nm (11 lb ft) Final Pass............................ .............................................................................................................................................................. ............30 Nm (22 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2168 Water Pump: Service and Repair Water Pump Replacement (With LH8) (5.3L) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Reposition the radiator inlet hose clamp (3) at the water pump. 6. Remove the radiator inlet hose from the water pump. 7. Reposition the radiator inlet hose and vent inlet hose out of the way. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2169 8. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 9. Reposition the radiator outlet hose clamp (1) at the water pump. 10. Remove the radiator outlet hose (2) from the water pump. 11. Reposition the outlet hose out of the way. 12. Reposition the radiator surge tank outlet hose clamp (1) at the water pump (2). 13. Remove the radiator surge tank outlet hose (3) from the water pump. 14. Reposition the outlet hose out of the way. 15. Reposition the heater inlet hose clamp (4) at the water pump. 16. Remove the heater inlet hose (5) from the water pump. 17. Reposition the inlet hose out of the way. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2170 18. Remove the water pump bolts (301). 19. Remove the water pump (300) and gaskets (309). Discard the gaskets. Installation Procedure Caution: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly. Note: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Position the water pump (300) and NEW gaskets (306) to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the water pump bolts (301). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2171 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). 2. Tighten the bolts a final pass to 30 Nm (22 lb ft). 3. Position and install the heater inlet hose (5) to the water pump. 4. Position the heater inlet hose clamp (4) at the water pump. 5. Position and install the radiator surge tank outlet hose (3) to the water pump. 6. Position the radiator surge tank outlet hose clamp (1) at the water pump (2). 7. Position and install the radiator outlet hose (2) to the water pump. 8. Position the radiator outlet hose clamp (1) at the water pump. 9. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2172 10. Position the radiator inlet hose and vent inlet hose to the correct position. 11. Install the radiator inlet hose to the water pump. 12. Position the radiator inlet hose clamp (3) at the water pump. 13. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 14. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 15. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Cooling System/Service and Repair). 16. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... .............................................. 13.7 quarts (13.0 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2178 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: Give freezing protection down to -34°F (-37°C). Give boiling protection up to 265°F (129°C). Protect against rust and corrosion. Help keep the proper engine temperature. Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (With LH8) (5.3L) Removal Procedure 1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine/Intake Manifold/Service and Repair). Otherwise proceed to the next step. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2182 7. Remove the coolant air bleed pipe (307) and seals (308). 8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed covers (313) and seals (308), if required. 10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2183 Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309) and tighten to 12 Nm (106 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2184 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required and tighten to 12 Nm (106 lb in). 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (See: Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Reservoir Replacement Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement Coolant Recovery Reservoir Replacement Removal Procedure 1. Partially drain the coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) or Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 3. Remove the coolant overflow hose (6) from the coolant recovery reservoir (5). 4. Remove the bolt (4) securing the coolant recovery reservoir (5) to the coolant recovery reservoir bracket. 5. Remove the radiator vent hose from the coolant recovery reservoir. 6. Remove the bolt securing the coolant recovery reservoir (5) to the front wheel house panel. 7. Remove the coolant recovery reservoir. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Reservoir Replacement > Page 2189 1. Install the coolant recovery reservoir. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the retaining bolt to the front wheelhouse panel and tighten the bolt to 12 Nm (106 lb in). 3. Install the radiator vent hose to the coolant recovery reservoir. 4. Install the bolt (4) securing the coolant recovery reservoir (5) to the coolant recovery reservoir bracket. Tighten the nut to 10 Nm (88 lb in). 5. Install the overflow hose (6) to the coolant recovery reservoir (5). 6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) or Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 7. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Reservoir Replacement > Page 2190 Coolant Reservoir: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Remove the vent inlet hose from the radiator. 3. Remove the retaining clips from the radiator vent inlet hose. 4. Remove the radiator vent inlet hose (3) from the coolant recovery reservoir (2). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Reservoir Replacement > Page 2191 1. Install the radiator vent inlet hose (3) to the coolant recovery reservoir (2). 2. Install the retaining clips to the radiator vent inlet hose. 3. Install the radiator vent inlet hose to the radiator. 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection Fan Clutch: Testing and Inspection Fan Clutch Diagnosis Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 2196 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 2197 Fan Clutch: Service and Repair Fan Clutch Replacement Removal Procedure 1. Remove the cooling fan. Refer to Fan Replacement (LH8) (See: Service and Repair)Fan Replacement (LLV, LLR) (See: Service and Repair). 2. Remove the bolts retaining the fan blade to the fan clutch. 3. Separate the fan blade from the fan clutch. Installation Procedure 1. Assemble the fan to the fan clutch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 bolts to the fan blade and tighten to 27 Nm (20 lb ft). 3. Install the cooling fan. Refer to Fan Replacement (LH8) (See: Service and Repair)Fan Replacement (LLV, LLR) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2202 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2203 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair )Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 3. Remove the ECT sensor (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2204 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Install the ECT sensor (1). Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2205 Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Engine Coolant Fan Shroud Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Heater Core Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair). 2. Remove the heater core pipes clamp screw (3). 3. Remove the heater core pipes clamp (2). 4. Remove the heater core clamp screws. 5. Remove the heater core clamp (2). 6. Remove the heater core from the HVAC module. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 2212 1. Install the heater core to the HVAC module. 2. Install the heater core clamp (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the heater core clamp screws. Tighten the screws to 1.9 Nm (17 lb in). 4. Install the heater core pipes clamp (2). 5. Install the heater core pipes clamp screw (3). Tighten the screw to 20 Nm (15 lb ft). 6. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement Tools Required * J 38185 Hose Clamp Pliers * J 43181 Heater Line Quick Connect Release Tool Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Using the J 43181 , release the inlet heater hose quick connect (1) from the heater core inlet. 3. Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Remove the heater inlet hose (3) from the inlet hose fitting (6) at the engine block. 5. Remove the heater inlet hose (3). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2217 1. Apply coolant to the end of the heater inlet hose (5). Important: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose (3) to the inlet hose fitting (6) at the engine block. 3. Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Install the heater inlet hose (3) to the heater core inlet. 5. Press the quick connect (1) onto the heater core inlet until fully seated. 6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2218 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 3. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 4. Using the J 38185 disconnect the outlet hose from the heater core outlet tube. 5. Remove the heater outlet hose from the heater core. 6. Position the outlet heater hose clamp (6) at the water pump using J 38185 . 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 . 4. Install the heater outlet hose to the heater core. 5. Position the outlet heater hose clamp at the heater core using J 38185 . 6. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2219 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 8. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2220 Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2221 Heater Hose: Service and Repair Heater Inlet Pipe Replacement Heater Inlet Pipe Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Using the J 38185 , reposition the heater hose outlet clamp from the heater pipe inlet. 3. Remove the heater hose outlet from the heater pipe inlet. 4. Remove the exhaust heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR) (). 5. Remove the heater inlet pipe bolt. 6. Remove the heater inlet pipe. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2222 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3. Install the heater hose outlet to the heater pipe inlet. 4. Using the J 38185 , reposition the heater hose outlet clamp to the heater pipe inlet. 5. Install the exhaust heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR) (). 6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2223 Heater Hose: Service and Repair Heater Outlet Pipe Replacement Heater Outlet Pipe Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Using the J 38185 , reposition the heater hose inlet clamp from the heater pipe outlet. 3. Remove the heater hose inlet from the heater pipe outlet. 4. Loosen the heater pipe outlet. 5. Remove the heater pipe outlet. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 2224 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3. Install the heater hose inlet to the heater pipe outlet. 4. Using the J 38185 , reposition the heater hose inlet clamp to the heater pipe outlet. 5. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Replacement Special Tools J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV, LLR) (See: Fan Shroud/Service and Repair)Engine Coolant Fan Shroud Replacement (LH8) (See: Fan Shroud/Service and Repair). 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Using J 38185 reposition the radiator outlet hose clamp (2) from the radiator. 4. Remove the outlet radiator hose (1) from the radiator. 5. Remove the transmission cooler lines from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 6. Lower the vehicle. 7. Remove the radiator vent inlet hose from the radiator. 8. Remove the radiator mounting bracket bolt. 9. Remove the radiator mount. 10. Remove the grill. 11. Remove the condenser mounting bolts. 12. Separate the condenser from the radiator. 13. Remove the radiator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2228 Installation Procedure 1. Install the radiator. 2. Install the condenser to the radiator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts retaining the condenser to the radiator and tighten to 28 Nm (21 lb ft). 4. Install the grille. 5. Install the radiator mount bracket. 6. Install the radiator mounting bracket bolt and tighten to 28 Nm (21 lb ft). 7. Raise the vehicle. 8. Install the radiator outlet hose (1) to the radiator. 9. Using J 38185 reposition the radiator outlet hose clamp (2) to the radiator. 10. Connect the transmission cooler lines to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 11. Lower the vehicle. 12. Install the radiator vent inlet hose to the radiator. 13. Install the fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LLV, LLR) (See: Fan Shroud/Service and Repair)Engine Coolant Fan Shroud Replacement (LH8) (See: Fan Shroud/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing Special Tools J 24460-01 Cooling System Pressure Tester Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 in order to test the pressure cap. 4. Test the pressure cap for the following conditions: * Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. * Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: * The pressure cap does not release pressure which exceeds the rated pressure of the cap. * The pressure cap does not hold the rated pressure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 2236 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2242 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2243 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair )Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 3. Remove the ECT sensor (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2244 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Install the ECT sensor (1). Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2245 Draining and Filling (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Use a tempilstick in order to find the opening and the closing temperatures of the coolant thermostat. * J 24731-188 tempilstick melts at 87°C (188°F). The thermostat should begin to open at 90°C (194°F). * J 24731-206 tempilstick melts at 97°C (206°F). The thermostat should be fully open at 107°C (225°F). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2249 Thermostat: Service and Repair Engine Coolant Thermostat Replacement (LH8) (5.3L) Removal Procedure 1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (With LH8) (See: Thermostat Housing/Service and Repair). 2. Remove the thermostat. Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (With LH8) (See: Thermostat Housing/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Engine Coolant Thermostat Housing Replacement (With LH8) (5.3L) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Reposition the radiator outlet hose clamp (1) at the water pump inlet. 4. Remove the radiator outlet hose (2) from the water pump inlet. 5. Remove the water pump inlet bolts (1). 6. Remove the water pump inlet from the water pump. 7. Remove and discard the water pump inlet seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 2253 Installation Procedure 1. Install a NEW water pump inlet seal to the water pump inlet. 2. Position the water pump inlet to the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the water pump inlet bolts (1). Tighten the bolts to 15 Nm (11 lb ft). 4. Install the radiator outlet hose (2) to the water pump inlet. 5. Position the radiator outlet hose clamp (1) at the water pump inlet. 6. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 7. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 2254 (Vac N Fill) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP Water Pump Bolts First Pass................................................................................................................ .......................................................................................15 Nm (11 lb ft) Final Pass............................ .............................................................................................................................................................. ............30 Nm (22 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2258 Water Pump: Service and Repair Water Pump Replacement (With LH8) (5.3L) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Reposition the radiator inlet hose clamp (3) at the water pump. 6. Remove the radiator inlet hose from the water pump. 7. Reposition the radiator inlet hose and vent inlet hose out of the way. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2259 8. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 9. Reposition the radiator outlet hose clamp (1) at the water pump. 10. Remove the radiator outlet hose (2) from the water pump. 11. Reposition the outlet hose out of the way. 12. Reposition the radiator surge tank outlet hose clamp (1) at the water pump (2). 13. Remove the radiator surge tank outlet hose (3) from the water pump. 14. Reposition the outlet hose out of the way. 15. Reposition the heater inlet hose clamp (4) at the water pump. 16. Remove the heater inlet hose (5) from the water pump. 17. Reposition the inlet hose out of the way. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2260 18. Remove the water pump bolts (301). 19. Remove the water pump (300) and gaskets (309). Discard the gaskets. Installation Procedure Caution: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly. Note: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Position the water pump (300) and NEW gaskets (306) to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the water pump bolts (301). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2261 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). 2. Tighten the bolts a final pass to 30 Nm (22 lb ft). 3. Position and install the heater inlet hose (5) to the water pump. 4. Position the heater inlet hose clamp (4) at the water pump. 5. Position and install the radiator surge tank outlet hose (3) to the water pump. 6. Position the radiator surge tank outlet hose clamp (1) at the water pump (2). 7. Position and install the radiator outlet hose (2) to the water pump. 8. Position the radiator outlet hose clamp (1) at the water pump. 9. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2262 10. Position the radiator inlet hose and vent inlet hose to the correct position. 11. Install the radiator inlet hose to the water pump. 12. Position the radiator inlet hose clamp (3) at the water pump. 13. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 14. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 15. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Service and Repair). 16. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the 5 nuts securing the heat shield to the floor panel. 3. Remove the catalytic converter heat shield from the floor panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Service and Repair > Page 2268 1. Position the catalytic converter heat shield to the floor panel studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 5 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm (80 lb in). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications EXHAUST MANIFOLD Exhaust Manifold Bolts First Pass........................................................................................................ ...............................................................................................15 Nm (11 lb ft) Final Pass.................... .............................................................................................................................................................. ....................20 Nm (15 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Side Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Side Exhaust Manifold Replacement - Left Side (LH8) (5.3L) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the catalytic converter to exhaust manifold nuts (2). 3. Lower the vehicle. 4. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine/Intake Manifold/Service and Repair) 5. Remove the spark plugs. Refer to Spark Plug Replacement (See: Engine/Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 6. Disconnect the ignition coil bracket from the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) 7. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement Left Side (LH8) (See: Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement - Left Side). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2274 8. Remove the exhaust manifold bolts (1). 9. Remove the exhaust manifold (2) and gasket (3). Discard the gasket. Installation Procedure Note: * Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. * The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Note: Do not apply sealant to the first 3 threads of the bolt. 1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493, (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 2. Ensure that the exhaust seal is still seated on the catalytic converter recess. 3. Install one exhaust manifold bolt to the exhaust manifold (2) and place the NEW gasket (3) onto the bolt. 4. Install the exhaust manifold to the catalytic converter flange and position the manifold to the cylinder head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2275 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the remaining exhaust manifold bolts (1). 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 6. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head. 7. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (LH8) (See: Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement - Left Side). 8. Install the ignition coil bracket to the valve rocker arm cover. refer to Valve Rocker Arm Cover Replacement - Left Side (See: Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) 9. Install the spark plugs. Refer to Spark Plug Replacement (See: Engine/Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 10. Install upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine/Intake Manifold/Service and Repair) 11. Raise the vehicle. 12. Install the catalytic converter to exhaust manifold nuts (2). Tighten the nuts to 50 Nm (37 lb ft). 13. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2276 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side Exhaust Manifold Replacement - Right Side (LH8) (5.3L) 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the catalytic converter to exhaust manifold nuts (2). 3. Lower the vehicle. 4. Remove the spark plugs. Refer to Spark Plug Replacement (See: Engine/Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 5. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement Right Side (LH8) (See: Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement - Right Side). 6. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement (See: Engine/Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). 7. Remove the exhaust manifold bolts (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2277 8. Remove the exhaust manifold (2) and gasket (1). Discard the gasket. Installation Procedure Note: * Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. * The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Note: Do not apply sealant to the first 3 threads of the bolt. 1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493, (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 2. Ensure that the exhaust seal is still seated on the catalytic converter recess. 3. Install one exhaust manifold bolt to the exhaust manifold (2) and place the NEW gasket (1) onto the bolt. 4. Install the exhaust manifold to the catalytic converter flange and position the manifold to the cylinder head. 5. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement (See: Engine/Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the remaining exhaust manifold bolts (3). 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 7. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head. 8. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (LH8) (See: Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement - Left Side). 9. Install the spark plugs. Refer to Spark Plug Replacement (See: Engine/Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 10. Raise the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2278 11. Install the catalytic converter to exhaust manifold nuts. Tighten the nuts to 50 Nm (37 lb ft). 12. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair Exhaust Pipe/Muffler Hanger: Service and Repair Exhaust System Insulator, Hanger, Bracket Replacement Service the exhaust hangers individually in order to retain the support of the exhaust system. Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: Do not use oil base lubricants. 2. Apply a soapy solution to the following in order to ease the removal of the hanger (1): * The frame support bracket rod (2) * The exhaust pipe hanger rod (3) 3. Pry the exhaust pipe hanger (1) free from the following: * The frame support bracket rod (2) * The exhaust pipe hanger rod (3) Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Page 2282 Note: Do not use oil base lubricants. 1. Apply a soapy solution to the following in order to ease the installation of the hanger (1): * The frame support bracket rod (2) * The inner diameter of the exhaust pipe hanger (1) * The exhaust pipe hanger rod (3) 2. Press the exhaust pipe hanger (1) over the following: * The frame support bracket rod (2) * The exhaust pipe hanger rod (3) 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side (LH8) (5.3L) Removal Procedure 1. Open the hood. 2. Remove the exhaust manifold heat shield bolts (1) and shield (2). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the exhaust manifold heat shield (2) to the manifold and install the bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2287 Tighten the bolts to 9 Nm (80 lb in). 2. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2288 Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Left Side Exhaust Manifold Heat Shield Replacement - Left Side (LH8) (5.3L) Removal Procedure 1. Open the hood. 2. Remove the exhaust manifold heat shield bolts (1) and shield (2). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the exhaust manifold heat shield (2) to the manifold and install the bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2289 Tighten the bolts to 9 Nm (80 lb in). 2. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2290 Heat Shield: Service and Repair Exhaust Muffler Heat Shield Replacement Exhaust Muffler Heat Shield Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the 3 nuts securing the heat shield to the floor panel. 3. Remove the exhaust muffler heat shield from the floor panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2291 1. Position the exhaust muffler heat shield to the floor panel studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm (80 lb in). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2292 Heat Shield: Service and Repair Exhaust Pipe Heat Shield Replacement Exhaust Pipe Heat Shield Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the 4 nuts securing the heat shield to the floor panel. 3. Remove the exhaust pipe heat shield from the floor panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 2293 1. Position the exhaust pipe heat shield to the floor panel studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm (80 lb in). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Exhaust Muffler Replacement (LH8) (5.3L) Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: Use care not to over extend the rear brake hose. 2. Complete the following in order to gain clearance to remove the muffler: 1. Remove the lower shock absorber nuts (9) and bolts (8). 2. Remove the right rear leaf spring nut (2) and bolt (1). 3. Wedge a block of wood (5) between the frame (4) and the rear axle (6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2297 3. Remove the catalytic converter nuts (1). 4. Loosen the front exhaust muffler pipe at the catalytic converter clamp (2). 5. Separate the front exhaust muffler pipe hanger from the insulator. 6. Separate the front exhaust muffler pipe from the catalytic converters. Note: Do not use oil base lubricants. 7. Apply a soapy solution to the exhaust pipe hanger rods (3) in order to ease the removal of the exhaust hangers (1). 8. Pry the exhaust hangers (1) free from the exhaust pipe hanger rods (3). 9. Complete the following in order to remove the muffler from the vehicle: Note: It may be necessary to rotate the Muffler in order to gain clearance. 1. Slide the muffler rearward from the catalytic converter. 2. Carefully remove the muffler rearward from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2298 Caution: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position. 1. Complete the following in order to install the muffler to the vehicle: Note: It may be necessary to rotate the Muffler in order to gain clearance. 1. Carefully insert the muffler over the rear axle until the flange is near the catalytic converter. 2. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Note: Do not use oil base lubricants. 2. Apply a soapy solution to the following in order to ease the installation of the hangers (1): * The inner diameter of the exhaust pipe hanger (1) * The exhaust pipe hanger rod (3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2299 3. Position the front exhaust muffler pipe to the catalytic converters. 4. Install the front exhaust muffler pipe to the front exhaust insulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the catalytic converter nuts (1) and tighten to 45 Nm(33 lb ft). 6. Tighten the exhaust muffler clamp at the catalytic converter (2) and tighten to 43 Nm (32 lb ft). 7. Remove the block of wood (5) from between the frame (4) and rear axle (6). 8. Install the right rear leaf spring bolt (1) and nut (2) and tighten to 85 Nm (63 lb ft). 9. Install the lower shock absorber bolts (8) and nuts (9) and tighten to 95 Nm (70 lb ft). 10. Inspect the exhaust system for leaks and underbody contact. 11. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement (With LH8) (5.3L) Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. If removing the left side seal, remove the catalytic converter to exhaust manifold nuts (1). 3. Position the catalytic converter rearward enough in order to allow clearance to remove the seal. 4. Remove and discard the exhaust manifold seal (2). 5. If removing the right side seal, remove the catalytic converter to exhaust manifold nuts (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 2304 6. Position the catalytic converter rearward enough in order to allow clearance to remove the seal. 7. Remove and discard the exhaust manifold seal (1). Installation Procedure 1. If the right side seal was removed, position the catalytic converter rearward enough in order to allow clearance to install the seal. 2. Install a NEW exhaust manifold seal (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the catalytic converter to exhaust manifold nuts (2) and tighten to 50 Nm (37 lb ft. 4. If removing the left side seal, position the catalytic converter rearward enough in order to allow clearance to install the seal. 5. Install a NEW exhaust manifold seal (2). 6. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 50 Nm (37 lb ft). 7. Lower the vehicle. 8. Inspect for exhaust leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views Body Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2323 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2324 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2325 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2326 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2327 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2328 Body Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Right Kick Panel Components 1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body Control Module (BCM) X2 6 - Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2329 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2330 Body Control Module (BCM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2331 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2332 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2333 Body Control Module: Service and Repair Body Control Module Replacement Removal Procedure Important: * The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). * Always disconnect the black body wiring harness connector FIRST and the gray instrument panel (I/P) wiring harness connector LAST. * Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness LAST. * Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Disconnect the body wiring harness electrical connector (1) from the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2334 4. Disconnect the I/P wiring harness electrical connector (1) from the BCM. 5. Release the fastener retaining the body wiring harness electrical connector to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2335 6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle. Installation Procedure 1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3. Install the 2 fasteners retaining the BCM to the hinge pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2336 4. Install the fastener retaining the body wiring harness electrical connector to the BCM. 5. Connect the body wiring harness electrical connector (1) to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2337 6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2342 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2343 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2344 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2345 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2346 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2347 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2348 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2349 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2350 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views Engine Control Module: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2353 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2354 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2355 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2356 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Rear of the Engine Compartment Components - 1 of 2 1 - Engine Control Module (ECM) 2 - Front Plenum Panel Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2357 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2358 Engine Control Module (ECM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2359 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2360 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2361 Engine Control Module (ECM) X3 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2362 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2363 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2364 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2365 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should normally consist of either replacement of the ECM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). 3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from the ECM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2366 5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing the ECM (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2367 1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket. Ensure that the tabs (2) secure the ECM (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral CPA retainers on the engine wiring harness electrical connectors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2368 4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed, the ECM must be programmed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2372 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2373 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2374 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (K18) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 2383 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2390 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2391 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Relays and Modules - Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2392 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2399 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2400 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2401 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2402 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2403 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2404 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2405 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2406 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2410 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2411 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2415 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2416 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2420 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2421 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 3. Remove the ECT sensor (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2422 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Install the ECT sensor (1). Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2423 System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2427 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2430 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2431 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 2435 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1) from the module cover. 3. Complete the following in order to remove the fuel level sensor (1) from the module bucket: 1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 2436 1. Complete the following in order to install the fuel level sensor to the module bucket. 1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into position, ensure the locking tabs are fully engaged. 2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 2445 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 2451 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Pressure Sensor: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise Under Heavy Load Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Whine Noise Under Heavy Load TECHNICAL Bulletin No.: 09-01-38-002 Date: May 14, 2009 Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose With Updated Design) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped with Engine RPO LH8 Condition Some customers may comment on a moan and/or a whine type noise when the A/C compressor is engaged during high system loads. These high load operating conditions include high ambient temperatures, extended periods of idle operation and towing applications. The noise will stop immediately when the compressor is disengaged. Cause This condition may be caused by the factory installed A/C suction hose lacking sufficient noise dampening. Correction Install a new A/C suction hose assembly. This new hose assembly has an improved noise dampening design. Refer to Suction Hose Replacement (LH8) in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views Fuel Tank Pressure Sensor: Locations Harness Routing Views Harness Routing Views Chassis Harness Routing 1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400 (Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views > Page 2464 Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Rear of the Frame Components 1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2465 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2466 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor (1). 5. Pull upward in order to remove the sensor from the fuel tank module. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2467 1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4. Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 2471 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 2472 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2476 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2477 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2478 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2481 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2482 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2483 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2487 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2488 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2) from the intake manifold. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2489 1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the intake manifold. 3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 2493 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 2494 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Powertrain Component Views Rear of the Transmission Components 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2498 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2499 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2500 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 2503 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 2504 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 2505 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2508 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2509 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2510 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2511 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2512 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2513 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2514 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2515 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2516 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2517 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 2518 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2522 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2523 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2524 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2525 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2526 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Powertrain Component Views Left Side of the Transmission Components (MA5) Description 1 - Vehicle Speed Sensor (VSS) Inside the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2530 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2531 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2532 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS with O-ring seal. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 2535 Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install the VSS with O-ring seal. Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft). 2. Connect the VSS electrical connector (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 2536 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical connector from the vehicle speed sensor. 3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor (1). 6. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2542 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2543 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2544 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2545 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2546 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2547 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2548 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2549 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2553 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2554 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2559 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2560 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2564 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2567 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2568 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding This vehicle has two different types of ignition lock cylinders based on what type of steering column the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder designs. Ignition Lock Cylinder The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side. Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into the case assembly (5). 1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3. The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install this tumbler in the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4 tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8. Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct key into the lock cylinder. All tumblers (1) should be flush with the housing of the lock cylinder. 9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM Super Lube GM P/N 12346241 or equivalent light lithium grease. 10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front face of the rotor. If the slide piece is installed incorrectly, the key cannot insert into the rotor due to no access to the ramp. 11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock cylinder housing. Ensure that the actuator lever is inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should pivot on the pin against spring tension. 12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side with the security plug (3) faces to the left of the key head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2574 13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the center of the lock cylinder housing (1) and hold it. Insert the coded lock cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the housing. 15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward slightly. The key should be able to be removed and the lock cylinder should remain in the housing. 16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the lock cylinder housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2575 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4. Remove the ignition lock cylinder case. Installation Procedure 1. Install the ignition lock cylinder case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition switch, a passlock relearn will be needed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining pin down. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2576 5. Pull the ignition lock cylinder away from the steering column. Installation Procedure 1. Install the ignition lock cylinder by performing the following procedure: 1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until the retaining pin locks it in place. 2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2580 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2581 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2582 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2585 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2586 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2587 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure (Ignition ON, engine OFF)............................................................................................. ..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than 34 kPa (5 psi) in 1 minute Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2592 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2593 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Fuel Pressure Gage * J 37287 - Fuel Line Shut-Off Adapters Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal). 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2594 ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gage. The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test normal, replace the fuel sender. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (See: Fuel Delivery and Air Induction/Fuel Return Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2599 4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6. Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing. Installation Procedure 1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to engage the duct to the ball stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the air cleaner outlet duct clamp (1) at the throttle body. Tighten the clamp to 3.5 Nm (31 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2600 4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing. Tighten the clamp to 3.5 Nm (31 lb in). 5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Release the air cleaner upper housing retainer clips (1). 3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2604 1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper housing (1). 3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2610 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2611 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2612 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 2613 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2620 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. * Twist each spark plug 1/2 turn. * Pull only on the boot in order to remove the wire from each spark plug. 2. Remove the spark plug wire from the ignition coil. * Twist each spark plug boot 1/2 turn. * Pull only on the boot in order to remove the wires from the ignition coil. Installation Procedure 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the wires for proper installation: * Push sideways on each boot in order to inspect the seating. * Reinstall any loose boot. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2629 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2630 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2636 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 2637 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2638 Spark Plug: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2639 Spark Plug: Application and ID Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2640 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1) - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3,4). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2641 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A looses center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2642 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Ignition System/Specifications). 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the spark plug. Tighten the plug to 20 Nm (15 lb ft). 5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2646 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2652 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2653 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2654 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2655 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2656 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2657 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2658 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2659 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2663 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2664 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 2668 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 2669 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views Body Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2685 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2686 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2687 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2688 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2689 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 2690 Body Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Right Kick Panel Components 1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body Control Module (BCM) X2 6 - Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2691 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2692 Body Control Module (BCM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2693 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2694 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2695 Body Control Module: Service and Repair Body Control Module Replacement Removal Procedure Important: * The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). * Always disconnect the black body wiring harness connector FIRST and the gray instrument panel (I/P) wiring harness connector LAST. * Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness LAST. * Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Disconnect the body wiring harness electrical connector (1) from the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2696 4. Disconnect the I/P wiring harness electrical connector (1) from the BCM. 5. Release the fastener retaining the body wiring harness electrical connector to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2697 6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle. Installation Procedure 1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3. Install the 2 fasteners retaining the BCM to the hinge pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2698 4. Install the fastener retaining the body wiring harness electrical connector to the BCM. 5. Connect the body wiring harness electrical connector (1) to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 2699 6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2703 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2704 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2708 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2709 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 3. Remove the ECT sensor (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2710 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Install the ECT sensor (1). Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2711 System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2715 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2718 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2719 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Harness Routing Views Data Link Connector: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Harness Routing Views > Page 2724 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Harness Routing Views > Page 2725 Data Link Connector: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Below the I/P Components - 1 of 2 1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2726 Data Link Connector: Diagrams Component Connector End Views Data Link Connector (DLC) Data Link Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2727 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation Electronic Throttle Actuator: Description and Operation Throttle Actuator Control (TAC) System Description Purpose The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable. The TAC system performs the following functions: * Accelerator pedal position sensing * Throttle positioning to meet driver and engine demands * Throttle position sensing * Internal diagnostics * Cruise control functions * Manage TAC electrical power consumption The TAC system includes the following components: * The accelerator pedal position (APP) sensors * The throttle body assembly * The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal contains 2 individual APP sensors within the assembly. The Accelerator Pedal Position (APP) sensors 1 and 2 are potentiometer type sensors each with 3 circuits: * A 5-volt reference circuit * A low reference circuit * A signal circuit The APP sensors are used to determine the pedal angle. The engine control module (ECM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the ECM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is less than 1 volt and increases to above 4 volts as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near 0.5 volt and increases to more than 2 volts as the pedal is actuated. Throttle Body Assembly The throttle assembly contains the following components: * The throttle blade * The throttle actuator motor * The throttle position (TP) sensor 1 and 2 The throttle body functions similar to a conventional throttle body with the following exceptions: * An electric motor opens and closes the throttle valve. * The throttle blade is spring loaded in both directions and the default position is slightly open. * There are 2 individual TP sensors within the throttle body assembly. The TP sensors are used to determine the throttle plate angle. The TP sensors provide the engine control module (ECM) with a signal voltage proportional to throttle plate movement. The TP sensor 1 signal voltage at closed throttle is above 4 volts and decreases as the throttle plate is opened. The TP sensor 2 signal voltage at closed throttle is below 1 volt and increases as the throttle plate is opened. Engine Control Module The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the drivers intent and then calculates the appropriate throttle response. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor. Modes of Operation Normal Mode During the operation of the throttle actuator control (TAC) system, several modes or functions are considered normal. The following modes may be entered during normal operation: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation > Page 2731 * Minimum pedal value-At key-up the engine control module (ECM) updates the learned minimum pedal value. * Minimum throttle position (TP) values-At key-up the ECM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position. * Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction. * Battery saver mode-After a predetermined time without engine RPM, the ECM commands the battery saver mode. During the battery saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: * Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control; however, the vehicle acceleration is limited. * Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control; however, the maximum throttle opening is limited. * Throttle default mode-The ECM will turn off the throttle actuator motor and the throttle will return to the spring loaded default position. * Forced idle mode-The ECM will perform the following actions: - Limit engine speed to idle by positioning the throttle position, or by controlling the fuel and spark if the throttle is turned off. - Ignore the accelerator pedal input. * Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2736 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2737 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2738 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2739 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2740 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2741 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2742 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2743 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2744 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views Engine Control Module: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2747 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2748 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2749 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 2750 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Rear of the Engine Compartment Components - 1 of 2 1 - Engine Control Module (ECM) 2 - Front Plenum Panel Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2751 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2752 Engine Control Module (ECM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2753 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2754 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2755 Engine Control Module (ECM) X3 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2756 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2757 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2758 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2759 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should normally consist of either replacement of the ECM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). 3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from the ECM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2760 5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing the ECM (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2761 1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket. Ensure that the tabs (2) secure the ECM (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral CPA retainers on the engine wiring harness electrical connectors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2762 4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed, the ECM must be programmed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Recalls for Fuel Injector Control Module: > NHTSA09V154000 > May > 09 > Recall 09V154000: Fuel System Control Module Shorting Fuel Injector Control Module: Recalls Recall 09V154000: Fuel System Control Module Shorting VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009 Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009 Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009 GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: May 06, 2009 NHTSA CAMPAIGN ID NUMBER: 09V154000 NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline POTENTIAL NUMBER OF UNITS AFFECTED: 27188 SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV) seal between the seal and the housing may allow water to seep into the module. CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start, may not start or may stall increasing the risk of a crash. REMEDY: Dealers will install a new fuel system control module free of charge. The recall is expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: > NHTSA09V154000 > May > 09 > Recall 09V154000: Fuel System Control Module Shorting Fuel Injector Control Module: All Technical Service Bulletins Recall 09V154000: Fuel System Control Module Shorting VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009 Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009 Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009 GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: May 06, 2009 NHTSA CAMPAIGN ID NUMBER: 09V154000 NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline POTENTIAL NUMBER OF UNITS AFFECTED: 27188 SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV) seal between the seal and the housing may allow water to seep into the module. CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start, may not start or may stall increasing the risk of a crash. REMEDY: Dealers will install a new fuel system control module free of charge. The recall is expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 2779 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1) from the module cover. 3. Complete the following in order to remove the fuel level sensor (1) from the module bucket: 1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 2780 1. Complete the following in order to install the fuel level sensor to the module bucket. 1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into position, ensure the locking tabs are fully engaged. 2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 2789 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 2795 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views Fuel Tank Pressure Sensor: Locations Harness Routing Views Harness Routing Views Chassis Harness Routing 1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400 (Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views > Page 2798 Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Rear of the Frame Components 1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2799 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2800 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor (1). 5. Pull upward in order to remove the sensor from the fuel tank module. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2801 1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4. Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2806 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2808 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2809 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2810 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2812 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2813 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2814 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2815 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2816 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2817 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2818 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2819 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2820 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2821 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2822 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2823 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2824 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2825 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2826 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2828 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2829 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2830 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2831 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2832 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2833 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2834 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2835 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2836 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2837 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2838 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2839 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2840 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2841 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2842 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2843 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2844 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 Information Bus: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2916 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2917 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2918 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2919 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2920 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2945 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2959 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2960 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2961 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2962 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2969 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2970 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2973 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2974 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Information Bus: Electrical Diagrams Data Communication Schematics Class 2 Serial Data High Speed GMLAN Serial Data Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2979 Information Bus: Description and Operation Data Link Communications Description and Operation Circuit Description The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data line. The serial data line is the means by which the microprocessor-controlled modules in the vehicle communicate with each other. Once the scan tool is connected to the class 2 serial data line through the DLC, the scan tool can be used to monitor each module for diagnostic purposes and to check for diagnostic trouble codes (DTCs). Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. Data Link Connector (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Scan tool power battery positive voltage at terminal 16 * Scan tool power ground at terminal 4 * Class 2 serial data at terminal 2 * Common signal ground at terminal 5 Class 2 Serial Data Line The class 2 serial data line on this vehicle is a combination ring-star configuration, where body control module (BCM) is connected to multiple modules. Refer to Data Communication Schematics (See: Diagrams/Electrical Diagrams). The following modules communicate on class 2 bus: * The BCM * The communication interface module (OnStar(R)), w/UE1 * The digital radio receiver (DRR), w/U2K * The electronic brake control module (EBCM) * The inflatable restraint sensing and diagnostic module (SDM) * The instrument panel cluster (IPC) * The powertrain control module (PCM) * The radio * The transfer case shift control module (TCSCM), w/4WD Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Data Communications Diagnostic Starting Point - Data Communications Begin the system diagnosis with Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). The Diagnostic System Check - Vehicle will provide the following information: * The identification of the control modules which are not communicating * The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Data Link References Data Link References This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation (See: Description and Operation). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2982 Information Bus: Symptom Related Diagnostic Procedures Symptoms - Data Communications Symptoms - Data Communications Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the systems. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up) * Scan Tool Does Not Communicate with Class 2 Device (See: Scan Tool Does Not Communicate with Class 2 Device) * Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not Communicate with High Speed GMLAN Device) Scan Tool Does Not Communicate with Class 2 Device Scan Tool Does Not Communicate with Class 2 Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data circuit is the means by which the control modules connected to it communicate with each other. Once the scan tool is connected to the Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2983 class 2 serial data circuit through the DLC, the scan tool can be used to monitor each control module for diagnostic purposes and to check for diagnostic trouble codes (DTCs). Class 2 serial data is transmitted on a single wire at an average of 10.4 Kbps. The bus is active at 7.0 volts nominal and inactive at ground potential. When the ignition switch is in RUN, each control module communicating on the class 2 serial data circuit sends a state of health (SOH) message to ensure that the control module is operating properly. When a control module stops communicating on the class 2 serial data circuit, for example if the control module loses power or ground, the SOH message it normally sends on the data circuit disappears. Other control modules on the class 2 serial data circuit, which expect to receive that SOH message, detect its absence; those control modules in turn set an internal DTC associated with the loss of SOH of the non-communicating control module. The DTC is unique to the control module which is not communicating, for example, when the body control module (BCM) SOH message disappears, several control modules set DTC U1064. Note that a loss of serial data DTC does not normally represent a failure of the control module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: * A control module on the data communication circuit was disconnected while the communication circuit is awake. * Power to one or more modules was interrupted during diagnosis * A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. * Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. * If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue * Communication may be available between the BCM and the scan tool with the low speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * An open between the DLC and the BCM will only effect the communication with the scan tool. The vehicle modules will still communicate, and the vehicle will start. * The engine will not start when there is a total malfunction of the low speed GMLAN serial data circuit. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed LAN communications with the scan tool. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: * Vehicle will not crank. * Vehicle cranks but will not start. * Vehicle stability enhancement system warning lights and messages. * PRNDL gear indicator position errors. * Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Circuit/System Testing Note: Use the schematic to identify the following: * Control modules the vehicle is equipped with * Control module locations on the class 2 serial data circuit * The class 2 serial data circuit terminals for each control module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2984 1. Attempt to communicate with all control modules on the class 2 serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview/Data Link References). Communications should not be available with two or more control modules on the class 2 serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer to DTC U1001-U1254 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1001). ‹› If one or more control modules are communicating but not all, refer to Testing the Serial Data Circuit for an Open/High Resistance. 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuit terminal 2 and ground. ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuit for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuit terminal 2 and ground. ‹› If less than the specified range, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuit for a Short to ground. 6. Disconnect the appropriate harness connector at the BCM. 7. Test for less than 2 ohm between the DLC serial data circuit terminal 2 and the BCM connector. ‹› If greater than the specified range, test the serial data circuit for an open/high resistance. If the circuits test normal, replace the BCM. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Ignition ON, test for less than 4.5 V between the DLC serial data circuit terminal 2 and ground. ‹› If greater than the specified range, repair the short to voltage. 3. Test for less than 4.5 V between each serial data circuit at the BCM connectors and ground. ‹› If greater than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to voltage. If the circuit tests normal, replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to voltage. If the circuits test normal, replace the control module that causes the short to voltage when connected. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Test for infinite resistance between the DLC serial data circuit terminal 2 and ground. ‹› If not the specified value, repair the short to ground. 3. Ignition OFF for 60 seconds, test for greater than 100 ohm between each serial data circuit at the BCM connectors and ground. ‹› If less than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to ground. If the circuit tests normal, replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to voltage. If the circuits test normal, replace the control module that causes the short to ground when connected. Testing the Serial Data Circuit for an Open/High Resistance 1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Install a 3A fused jumper wire between the disconnected BCM connector DLC terminal and a class 2 serial data circuit that is not communicating. 3. Ignition ON, verify the scan tool communicates with the control modules connected to the class 2 serial data circuit. ‹› If any control module does not communicate, test each section of the serial data circuit for an open/high resistance. If the circuits test normal, replace the control module that does not communicate when connected. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2985 Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Control Module References (See: Testing and Inspection/Programming and Relearning) for module replacement, setup, and programming Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate with High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U code. The U code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2986 attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * High speed GMLAN serial data circuit terminating resistors * Control module locations on the high speed GMLAN serial data circuits * Each control module's high speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview/Data Link References). Communications should not be available with two or more control modules on the high speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer to DTC U0100-U0299 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2987 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 6 and terminal 14. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules * A short to ground on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuits Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2988 shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Scan Tool Does Not Power Up Scan Tool Does Not Power Up Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2989 required to provide the following: * Scan tool power battery positive voltage at terminal 16 * Scan tool power ground at terminal 4 * Common signal ground at terminal 5 Diagnostic Aids * The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. * If the battery positive voltage, ground circuits and connections of the DLC are functioning properly, the malfunction must be due to the scan tool/CANdi module. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing 1. Ignition ON, test for battery voltage between the battery positive voltage circuit of the DLC and ground. ‹› If less than battery voltage, test the voltage supply circuit for a short to ground or an open/high resistance. 2. Test for less than 1.0 ohm between the ground circuit of the DLC and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. If all tests normal, refer to the scan tool/CANdi module user guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2993 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2994 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2995 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2998 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 2999 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3000 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3004 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3005 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3006 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 3010 * Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3014 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3015 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2) from the intake manifold. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3016 1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the intake manifold. 3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3020 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3021 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Powertrain Component Views Rear of the Transmission Components 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3025 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3026 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3027 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3030 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3031 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3032 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3035 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3036 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3037 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3038 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3039 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3040 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3041 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3042 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3043 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3044 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3045 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views Body Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 3062 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 3063 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 3064 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 3065 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 3066 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 3067 Body Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Right Kick Panel Components 1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body Control Module (BCM) X2 6 - Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3068 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3069 Body Control Module (BCM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3070 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3071 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3072 Body Control Module: Service and Repair Body Control Module Replacement Removal Procedure Important: * The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). * Always disconnect the black body wiring harness connector FIRST and the gray instrument panel (I/P) wiring harness connector LAST. * Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness LAST. * Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Disconnect the body wiring harness electrical connector (1) from the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3073 4. Disconnect the I/P wiring harness electrical connector (1) from the BCM. 5. Release the fastener retaining the body wiring harness electrical connector to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3074 6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle. Installation Procedure 1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3. Install the 2 fasteners retaining the BCM to the hinge pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3075 4. Install the fastener retaining the body wiring harness electrical connector to the BCM. 5. Connect the body wiring harness electrical connector (1) to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3076 6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3081 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3082 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3083 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3084 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3085 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3086 Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3087 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3088 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3089 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views Engine Control Module: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 3092 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 3093 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 3094 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Harness Routing Views > Page 3095 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Rear of the Engine Compartment Components - 1 of 2 1 - Engine Control Module (ECM) 2 - Front Plenum Panel Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3096 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3097 Engine Control Module (ECM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3098 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3099 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3100 Engine Control Module (ECM) X3 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3101 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3102 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3103 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3104 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should normally consist of either replacement of the ECM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Remove the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). 3. Disengage the integral connector position assurance (CPA) retainer (1) on the body wiring harness electrical connector. 4. Disconnect the body wiring harness electrical connector (2) from the ECM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3105 5. Disengage the integral CPA retainers on the engine wiring harness electrical connectors. 6. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 7. Lift up the ECM bracket tabs (2) and tilt the ECM (1) towards the front of the vehicle, removing the ECM (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3106 1. Set the bottom of the ECM (1) into the bracket, and push the top of the ECM against the bracket. Ensure that the tabs (2) secure the ECM (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Engage the integral CPA retainers on the engine wiring harness electrical connectors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3107 4. Connect the body wiring harness electrical connector (2) to the ECM. 5. Engage the integral CPA retainer (1) on the body wiring harness electrical connector. 6. If a NEW ECM was installed, the ECM must be programmed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 7. Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3111 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3112 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3113 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3119 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3120 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3121 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3122 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3123 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3124 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3125 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3126 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3130 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3131 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3135 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3136 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3140 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3141 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 3. Remove the ECT sensor (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3142 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent. 2. Install the ECT sensor (1). Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 4. Refill the cooling system as required. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3143 System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3147 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3150 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3151 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 3155 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1) from the module cover. 3. Complete the following in order to remove the fuel level sensor (1) from the module bucket: 1. Disengage the locking tabs on the sensor. 2. Slide the sensor upward from the bucket. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 3156 1. Complete the following in order to install the fuel level sensor to the module bucket. 1. Align the edges of the sensor with the slots in the module bucket. 2. Slide the sensor down into position, ensure the locking tabs are fully engaged. 2. Connect the fuel level sensor electrical connector (1) to the module cover. 3. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 3165 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0451/P0454 Set TECHNICAL Bulletin No.: 10-06-04-001C Date: December 08, 2010 Subject: Intermittent MIL/Check Engine Light On, DTC P0451 or P0454 (Install Fuel Tank Pressure Sensor Cover) Models: 2009-2010 Chevrolet Cobalt, Colorado (Built Prior to January 13, 2010), Silverado (Built Prior to November 4, 2009) 2009-2010 GMC Canyon (Built Prior to January 13, 2010), Sierra (Built Prior to November 4, 2009) 2009-2010 Pontiac G5 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 10-06-04-001B (06 - Engine/Propulsion System). Condition Some customers may comment on a check engine light. Upon further investigation, a technician may find one of the above DTCs. Cause This condition may be caused by normal water accumulation or condensation blocking the air reference port of the fuel tank pressure sensor. Blockage can cause inaccurate output signals. If the signal varies during an Engine Off Natural Vacuum test, a false DTC could set. Correction Review the diagnostic information contained in SI for the DTC and repair as necessary. If SI diagnosis does not isolate the cause of this concern, ONLY install a fuel pressure sensor shield, P/N 20893611. Clear the DTCs. Chevrolet Colorado, Silverado and GMC Canyon, Sierra 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Place a suitable adjustable jack under the fuel tank. 3. Remove the fuel tank strap bolts. 4. Remove the fuel tank straps. 5. Lower the fuel tank halfway. 6. Locate the fuel tank pressure sensor (1). 7. Install the fuel tank pressure sensor cover, GM P/N 20893611. Chevrolet Cobalt and Pontiac G5 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 10-06-04-001C > Dec > 10 > Engine Controls - MIL ON/DTC's P0451/P0454 Set > Page 3171 2. Install the fuel tank pressure sensor cover (1), GM P/N 20893611. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views Fuel Tank Pressure Sensor: Locations Harness Routing Views Harness Routing Views Chassis Harness Routing 1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400 (Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Harness Routing Views > Page 3174 Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Rear of the Frame Components 1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3175 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3176 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. If the vehicle is crew cab, lower the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 4. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor (1). 5. Pull upward in order to remove the sensor from the fuel tank module. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3177 1. Lightly lubricate the sensor seal with clean engine oil. 2. Press the sensor fully into the fuel tank module. 3. Connect the chassis wiring harness electrical connector to the pressure sensor (1). 4. Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 5. If the vehicle is a crew cab, install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3181 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3182 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3186 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3187 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3188 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3191 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3192 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3193 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3197 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3198 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer (1) from the intake manifold. 4. Remove the MAP sensor (2) from the intake manifold. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3199 1. Install the MAP sensor (2) into the intake manifold. 2. Install the MAP sensor retainer (2) to the intake manifold. 3. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 4. Install the upper intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3203 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 3204 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Powertrain Component Views Rear of the Transmission Components 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3208 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3209 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (LH8) Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3210 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3213 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3214 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3215 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3218 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3219 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3220 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3221 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3222 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3223 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (2) from the engine wiring harness electrical connector (1). 3. Remove the HO2S wiring from under the rear HO2S electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3224 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (1). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3225 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). 3. Route the HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3226 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3227 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 3. Remove the HO2S (2). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3228 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Ensure to route the front HO2S wiring under the rear HO2S electrical connector. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3232 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3233 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3234 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3235 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3236 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Powertrain Component Views Left Side of the Transmission Components (MA5) Description 1 - Vehicle Speed Sensor (VSS) Inside the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3240 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3241 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3242 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 Manual Transmission Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS with O-ring seal. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 Manual Transmission > Page 3245 Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install the VSS with O-ring seal. Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft). 2. Connect the VSS electrical connector (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 Manual Transmission > Page 3246 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical connector from the vehicle speed sensor. 3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor (1). 6. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3250 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3251 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3252 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3253 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3254 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams Variable Valve Timing Solenoid: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Powertrain Component Views Left Side of the Transmission Components (MA5) Description 1 - Vehicle Speed Sensor (VSS) Inside the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3261 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3262 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3263 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission Vehicle Speed Sensor: Service and Repair Aisin AR5 - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS with O-ring seal. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 3266 Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install the VSS with O-ring seal. Tighten the vehicle speed sensor (VSS) to 17 Nm (13 lb ft). 2. Connect the VSS electrical connector (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Aisin AR5 - Manual Transmission > Page 3267 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the wiring harness electrical connector from the vehicle speed sensor. 3. Remove the harness connector. 4. Remove the bolt (2). 5. Remove the vehicle speed sensor (1). 6. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolt (2) and tighten to 11 Nm (97 lb in). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Diagrams Air Injection Pump: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump (K18) Secondary Air Injection (AIR) Pump Solenoid (K18) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Diagrams > Page 3273 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (K18) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Engine, Cooling and Exhaust/Exhaust System/Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the 5 nuts securing the heat shield to the floor panel. 3. Remove the catalytic converter heat shield from the floor panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Service and Repair > Page 3281 1. Position the catalytic converter heat shield to the floor panel studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 5 nuts securing the heat shield to the floor panel. Tighten the heat shield nuts to 9 Nm (80 lb in). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams Canister Purge Solenoid: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Purge Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3286 Canister Purge Solenoid: Service and Repair Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Disconnect the engine EVAP line (1) quick connect fitting from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3287 4. Disconnect the engine wiring harness electrical connector (3) from the EVAP canister purge solenoid valve. 5. Using a small flat bladed tool, disengage the retaining tab, and remove the EVAP canister purge solenoid valve (1) from the fuel rail bracket. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3288 1. Using a small flat bladed tool, reposition the retaining tab if necessary. 2. Install the EVAP canister purge solenoid valve (1) to the fuel rail bracket. 3. Connect the engine wiring harness electrical connector (3) to the EVAP canister purge solenoid valve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3289 4. Connect the engine EVAP line (1) quick connect fitting to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 5. Connect the chassis EVAP line quick connect fitting (1) to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Wheels/Vehicle Underbody Component Views Canister Vent Valve: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Rear of the Frame Components 1 - Evaporative Emission (EVAP) Canister Vent Solenoid 2 - Fuel Tank Pressure (FTP) Sensor 3 Fuel Pump and Sender Assembly 4 - Fuel Pump Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Wheels/Vehicle Underbody Component Views > Page 3295 Canister Vent Valve: Locations Harness Routing Views Harness Routing Views Chassis Harness Routing 1 - Chassis Frame 2 - Fuel Tank Pressure (FTP) Sensor 3 - Fuel Pump and Sender Assembly 4 Evaporative Emission (EVAP) Canister Vent Solenoid 5 - X402 (Chassis Harness to Right Rear Lamp Assembly) 6 - J404 7 - X401 (Chassis Harness to Left Rear Lamp Assembly) 8 - X400 (Chassis Harness to License Lamp Harness) 9 - J403 10 - J402 11 - J400 12 - J401 13 - J310 14 X102 (Body Harness to Chassis Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3296 Canister Vent Valve: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Vent Solenoid Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3297 Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the evaporative emission (EVAP) canister vent solenoid valve electrical connector (1). 3. Disconnect the fuel fill pipe vapor line quick connect (1) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3298 4. Disconnect the EVAP canister vent solenoid valve quick connect from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 5. Disengage the bracket retaining tab and remove the EVAP canister vent solenoid valve (1). Installation Procedure 1. Engage the bracket retaining tab and install the EVAP canister vent solenoid valve (1). 2. Connect the EVAP canister vent solenoid valve quick connect to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3299 3. Connect the fuel fill pipe vapor line quick connect (1) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Connect the EVAP canister vent solenoid valve electrical connector (1). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See: Service Precautions/Technician Safety Information). Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Service Precautions/Vehicle Damage Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) in order to disconnect the evaporative emission (EVAP) hoses (1, 3) from the following: * The EVAP canister (5) * The vent valve 3. Disengage the EVAP hose (3) from the retaining clip on the fuel tank. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank > Page 3304 1. Secure the EVAP hose (3) to the retaining clip on the fuel tank. 2. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) in order to connect the EVAP hoses (1, 3) to the following: * The EVAP canister (5) * The vent valve 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank > Page 3305 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis Evaporative Emission Hose/Pipe Replacement - Chassis Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See: Service Precautions/Technician Safety Information). Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Service Precautions/Vehicle Damage Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution). 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 3. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel pipe bracket nut (3) from the transmission stud. 6. Remove the fuel pipe bracket from the stud. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank > Page 3306 7. Disconnect the fuel tank fuel feed line quick connect fitting (4) from the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Disconnect the EVAP line quick connect fitting (1) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 9. Remove the chassis fuel feed and EVAP line bracket bolt (2). 10. Lift the chassis fuel feed and EVAP line assembly (3) up in order the remove the bracket tab from the crossmember. 11. Remove the fuel feed and EVAP line clip (4) from the fuel line bracket. 12. Remove the fuel pipe bracket bolt (6). 13. Remove the fuel feed and EVAP pipe assembly (3) from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank > Page 3307 1. Install the fuel feed and EVAP pipe assembly (3) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the fuel pipe bracket (5) and install the bracket bolt (6). Tighten the bolt to 4.5 Nm (40 lb in). 3. Install the fuel feed and EVAP line clip (4) to the fuel line bracket. 4. Position the chassis fuel feed and EVAP line assembly (3) bracket tab to the crossmember. 5. Install the chassis fuel feed and EVAP line bracket bolt (2). Tighten the bolt to 10 Nm (89 lb in). 6. Connect the EVAP line quick connect fitting (1) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank > Page 3308 7. Connect the fuel tank fuel feed line quick connect fitting (4) to the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Install the fuel pipe bracket onto the stud. 9. Install the fuel pipe bracket nut (3) to the transmission stud. Tighten the nut to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 12. Connect the chassis EVAP line quick connect fitting (1) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank > Page 3309 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine Evaporative Emission Hoses/Pipes Replacement - Engine Removal Procedure Important: Clean the tube connections and surrounding areas before disconnecting in order to avoid possible evaporative emission (EVAP) system contamination. 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine EVAP line (1) quick connect fitting from the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Disconnect the engine EVAP line (1) quick connect fitting from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Cap the intake manifold port and the EVAP canister purge solenoid valve in order to prevent possible EVAP system contamination. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank > Page 3310 1. Remove the caps from the intake manifold port and the EVAP canister purge solenoid valve. 2. Connect the engine EVAP line (1) quick connect fitting to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Connect the engine EVAP line (1) quick connect fitting to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting and left valve rocker arm cover, if required. 3. Remove the PCV tube (1) from the air cleaner outlet duct, if required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 3315 4. Remove the PCV tube (1) from the right valve rocker arm cover fitting (2), if required. 5. Remove the appropriate PCV hose/tube from the vehicle. Installation Procedure 1. Install the appropriate PCV hose/tube to the vehicle. 2. Install the PCV tube (1) to the right valve rocker arm cover fitting (2), if required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 3316 Important: Route the PCV tube between the engine harness and generator battery jumper cable. 3. Install the PCV tube (1) to the air cleaner outlet duct, if required. 4. Install the PCV hose to the intake manifold fitting and left valve rocker arm cover, if required. 5. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (K18) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure (Ignition ON, engine OFF)............................................................................................. ..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than 34 kPa (5 psi) in 1 minute Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3325 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3326 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Fuel Pressure Gage * J 37287 - Fuel Line Shut-Off Adapters Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal). 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3327 ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gage. The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test normal, replace the fuel sender. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (See: Fuel Return Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (See: Fuel Pump/Service and Repair) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3332 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3333 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3334 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3335 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3340 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3341 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3342 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3343 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3344 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3345 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3346 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3347 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3352 4. Loosen the air cleaner outlet duct clamp (1) at the throttle body. 5. Grasp the air cleaner outlet duct near the ball stud and firmly pull up in order to disengage the duct from the ball stud. 6. Remove the air cleaner outlet duct (2) from the throttle body and the air cleaner housing. Installation Procedure 1. Install the air cleaner outlet duct (2) to the throttle body and the air cleaner housing. 2. Ensure that the air cleaner outlet duct tab rests over the ball stud, press down on the duct tab in order to engage the duct to the ball stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the air cleaner outlet duct clamp (1) at the throttle body. Tighten the clamp to 3.5 Nm (31 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3353 4. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing. Tighten the clamp to 3.5 Nm (31 lb in). 5. Install the PCV line (1) to the air cleaner outlet duct. 6. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Release the air cleaner upper housing retainer clips (1). 3. Open the air cleaner upper housing (1). 4. Remove the air filter element (2) from the lower air cleaner housing. 5. Inspect the air cleaner assembly for debris or damage and repair as necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3357 1. Install the air filter element (2) to the lower air cleaner housing. 2. Close the air cleaner upper housing (1). 3. Latch the air cleaner upper housing retainer clips (1). 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3361 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3362 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. INFORMATION Bulletin No.: 10-06-04-015 Date: December 08, 2010 Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles Models: 2007-2011 GM Passenger Cars and Trucks General Motors' position regarding the Environmental Protection Agency announcement allowing the use of E 15 in 2007 and newer vehicles: - General Motors' remains focused on securing a safe and positive driving experience for our customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to confusion for consumers as to what fuel their vehicle should use. In response, we will continue to encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be used in GM vehicles that do not have a flex fuel designation. - GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15 percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However, ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel designation as they are not designed and certified to run on gasoline consisting of more than 10 percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual. - We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce petroleum dependence and the carbon footprint of driving. As the global leader in producing vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for the 2011 model year. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3367 Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3368 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3369 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3370 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3371 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3372 Fuel: Service Precautions Gasoline/Gasoline Vapors Warning Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool) Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool) Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool) Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. Alcohol in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.4 oz) specified cylinder with 1 ml (0.03 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.4 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.13 gal) of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles are found clean the entire fuel system thoroughly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool) > Page 3375 Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (with Special Tool) Alcohol/Contaminants-in-Fuel Diagnosis (with Special Tool) Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling , or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. Test Procedure 1. Test the fuel composition using J 44175 Fuel Composition Tester and J44175-3 Instruction Manual. 2. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 3. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank. 4. Test the fuel composition. 5. If testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3381 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Pressure Relief (Without CH-48027)). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3382 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3383 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (Without CH-48027) > Page 3384 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3393 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3394 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3395 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 3396 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3402 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3403 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3404 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 3405 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector (w/J39021 or w/Tech 2) Fuel Injector Resistance............................................................ .............................................................................................................................11-14 ohms Fuel Injector (W/CH47976) Fuel Injector Resistance........................................................................... ..............................................................................................................11-14 ohms Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3408 Fuel Injector: Pressure, Vacuum and Temperature Specifications The difference between any individual pressure drop and the average pressure drop should not be more than 20 kPa (3 psi) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3409 Fuel Injector: Diagrams Component Connector End Views Fuel Injector 1 (LH8) Fuel Injector 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3410 Fuel Injector 3 (LH8) Fuel Injector 4 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3411 Fuel Injector 5 (LH8) Fuel Injector 6 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3412 Fuel Injector 7 (LH8) Fuel Injector 8 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3413 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (W/CH47976) Fuel Injector Diagnosis (w/CH47976) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. The CH-47976 , is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests automatically and display results of the test. The results can also be down loaded for storage and printing. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Special Tools CH-47976 Active Fuel Injector Tester Component Testing Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Active Fuel Injector Tester (AFIT) Test Procedure. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. ‹› If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3416 Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. AFIT Test Procedure 1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. Refer to the AFIT User Guide. 4. Turn ON the AFIT and select the vehicle. 5. Turn ON the ignition and perform the Injector Test. ‹› If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 6. View the test results. ‹› If any injector exceeds the recommended tolerance, replace the injector(s), E-85 only. All other engine, refer to Fuel Injector Cleaning (See: Service and Repair/Procedures). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair/Removal and Replacement) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3417 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (w/J39021 or w/Tech 2) Fuel Injector Diagnosis (w/J39021 or w/Tech 2) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the system fuel pressure that can be recorded and used to compare each injector. Diagnostic Aids * Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. * Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. * Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH-48027 Digital Pressure Gage * J 39021 Fuel Injector Coil and Balance Tester * J 44602 Injector Test Adapter Component Testing Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3418 * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Fuel Injector Balance Test - Fuel Pressure Test. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. ‹› If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test - Fuel Pressure Test for further diagnosis of the fuel injectors. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Fuel Injector Balance Test-Fuel Pressure Test 1. Install a CH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal). 2. Turn ON the ignition, with the engine OFF. Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 3. Command the fuel pump relay ON with a scan tool. 4. Observe the fuel pressure gage with the fuel pump commanded ON. The fuel pressure should be 345-414 kPa (50-60 psi). ‹› If the fuel pressure is not 345-414 kPa (50-60 psi), refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 5. Monitor the CH-48027 for one minute. The fuel pressure should not decrease more than 34 kPa (5 psi). ‹› If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 6. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with Tech 2. Fuel Injector Balance Test with Special Tool 1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5 amp position. 2. Connect the J 39021 to a fuel injector with a J 44602 . 3. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 4. Command the fuel pump relay ON one more time and energize the fuel injector by depressing the Push to Start Test button on the J 39021 at the previously selected pressure. 5. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. 6. Clear the Min/Max results. 7. Select Normal from the Display Mode. 8. Repeat steps 2 and 4 through 7 for each fuel injector. 9. Perform the Pressure Drop Calculation. Fuel Injector Balance Test with Tech 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (W/CH47976) > Page 3419 1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027 and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. 7. Clear the Min/Max results on the CH-48027 . 8. Select Normal from the Display Mode on the CH-48027 . 9. Press Enter on the scan tool to bring you back to the Select Injector screen. 10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation. Pressure Drop Calculation 1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the pressure drop value. 2. Obtain a pressure drop value for each fuel injector. 3. Add all of the individual pressure drop values except for the injector suspected of being faulty. This is the total pressure drop. 4. Divide the total pressure drop by the number of fuel injectors that were added together. This is the average pressure drop. The difference between any individual pressure drop and the average pressure drop should not be more than 20 kPa (3 psi). ‹› If the difference between any individual pressure drop and the average pressure drop is more than 20 kPa (3 psi), replace the fuel injector, E-85 only. All other engine, refer to Fuel Injector Cleaning (See: Service and Repair/Procedures). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair/Removal and Replacement) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures Fuel Injector: Procedures Fuel Injector Cleaning Special Tools * J 37287 Fuel Line Shut-Off Adapters * J 35800-A Fuel Injector Cleaner * J 42873-1 3/8 Fuel Line Shut-Off Valve * J 42873-2 5/16 Return Pipe Shut-Off Valve * J 42964-1 3/8 Fuel Pipe Shut-Off Valve * J 42964-2 5/16 Fuel Pipe Shut-Off Valve Caution: * GM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. * Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank, as it may damage the fuel pump and other system components. * Do not exceed the recommended cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Note: Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced. 1. Obtain J 35800-A (2). Note: Make sure the valve at the bottom of the canister (3) is closed. 2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. 3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 5. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 6. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3422 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above procedure should be done. When the injector restriction returns to zero, proceed to step 12. 12. Disconnect the J 35800-A from the fuel rail. 13. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 14. Remove the J 37287 , or J 42964-1 and J 42964-2 , or J 42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines. 15. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011 (Canadian P/N 88861012) into a nearly empty tank and advise the customer to refuel with up to 76 L (20 gal) of fuel. 17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 18. Road test the vehicle to verify that the customer concern has been corrected. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3423 Fuel Injector: Removal and Replacement Fuel Injector Replacement Removal Procedure Caution: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. Note: The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel Rail/Service and Repair/Fuel Injection Fuel Rail Assembly Replacement). 2. Remove and discard the fuel injector retainer clip (4). 3. Remove the fuel injector (2). 4. Remove and discard the fuel injector O-ring seals (1 and 3). Installation Procedure Note: When ordering new fuel injectors, you must order the correct injector for the application being serviced. The fuel injector (1) is stamped with a identification part number (2). A 4-digit build date code (3) indicates the month (4), day (5), year (6), and the shift (7) that built the injector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3424 1. Lubricate the NEW injector O-ring seals (2 and 4) with clean engine oil. 2. Install the NEW injector O-ring seals (2 and 4) onto the injector (3). 3. Install a NEW retainer clip (1) on the injector (3). 4. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket. 5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel Rail/Service and Repair/Fuel Injection Fuel Rail Assembly Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Recalls for Fuel Injector Control Module: > NHTSA09V154000 > May > 09 > Recall 09V154000: Fuel System Control Module Shorting Fuel Injector Control Module: Recalls Recall 09V154000: Fuel System Control Module Shorting VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009 Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009 Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009 GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: May 06, 2009 NHTSA CAMPAIGN ID NUMBER: 09V154000 NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline POTENTIAL NUMBER OF UNITS AFFECTED: 27188 SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV) seal between the seal and the housing may allow water to seep into the module. CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start, may not start or may stall increasing the risk of a crash. REMEDY: Dealers will install a new fuel system control module free of charge. The recall is expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: > NHTSA09V154000 > May > 09 > Recall 09V154000: Fuel System Control Module Shorting Fuel Injector Control Module: All Technical Service Bulletins Recall 09V154000: Fuel System Control Module Shorting VEHICLE MAKE/MODEL: MODEL YEAR(S): Cadillac/Escalade 2009 Cadillac/Escalade ESV 2009 Cadillac/Escalade EXT 2009 Chevrolet/Avalanche 2009 Chevrolet/Colorado 2009 Chevrolet/Suburban 2009 Chevrolet/Tahoe 2009 GMC/Canyon 2009 GMC/Yukon 2009 GMC/Yukon XL 2009 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: May 06, 2009 NHTSA CAMPAIGN ID NUMBER: 09V154000 NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline POTENTIAL NUMBER OF UNITS AFFECTED: 27188 SUMMARY: GM is recalling 27,188 M/Y 2009 Cadillac Escalade, Escalade Hybrid, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Suburban, Tahoe, Tahoe Hybrid, and Colorado; and GMC Yukon, Yukon Hybrid, Yukon XL, and Canyon vehicles. The fuel system control modules may have a condition in which an adhesive separation of the Room Temperature Vulcanizing (RTV) seal between the seal and the housing may allow water to seep into the module. CONSEQUENCE: Water in the module could cause a short or open circuit, illumination of the service engine soon lamp, setting of diagnostic trouble codes or the engine may be hard to start, may not start or may stall increasing the risk of a crash. REMEDY: Dealers will install a new fuel system control module free of charge. The recall is expected to begin on or before May 18, 2009. Owners may contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438 and GMC at 1-866-996-9463 or at www.gmownercenter.com. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service Special Tools J 37088-A Fuel Line Disconnect Tool Set Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Remove the retainer from the quick-connect fitting. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct J 37088-A for the size of the fitting. Insert the J 37088-A into the female connector, then push inward in order to release the locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3442 5. Pull the connection apart. Caution: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Using a clean shop towel, wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Installation Procedure Warning In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push both sides of the quick-connect fitting together in order to snap the retaining tabs into place. 3. Pull on both sides of the quick-connect fitting to make sure the connection is secure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3443 4. Install the retainer to the quick-connect fitting. 5. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF, for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3444 Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Note: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. * Bartholomew (1) * Q Release (2) * Squeeze to Release (3) * Sliding Retainer (4) * Global Connect (5) * TI Loc (6) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). Warning: Refer to Safety Glasses and Compressed Air Warning (See: Service Precautions/Technician Safety Information/Safety Glasses and Compressed Air Warning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3445 Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution). 2. Using compressed air, blow any dirt out of the quick-connect fitting. 3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick-connect fitting release tabs. 4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3446 5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting. 6. This step applies to Squeeze to Release style connectors ONLY. Push in the male side slightly in order to slide the retainer away from the retainers, squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3447 7. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only move in one direction. 8. This step applies to the Global Connector style only. Push the connector toward the tube in order to release the pressure. Press and hold down the release mechanism, and pull the connector straight off the tube. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3448 9. This step applies to the TI Loc style only. Push the connector toward the tube in order to release the pressure. Release the redundant latch (1) with two fingers or a flat bladed tool. Then press and hold down the bottom release mechanism (2), and pull the connector straight off the tube. Quick Connect Fittings Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions). 10. Pull the connection apart. 11. Using a clean shop towel, wipe off the male pipe end. 12. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Installation Procedure Warning: Refer to Fuel Pipe Fitting Warning (See: Service Precautions/Fuel Pipe Fitting Warning). 1. Apply a few drops of clean engine oil to the male pipe end. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3449 2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place. 3. Pull on both sides of the quick-connect fitting to make sure the connection is secure. 4. Inspect for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF, for 10 seconds. 3. Turn the ignition ON, with the engine OFF for 2 seconds. 4. Turn the ignition OFF. 5. Inspect for leaks. 5. Apply a few drops of clean engine oil to the male pipe end. 6. Insert the tube in the connector until the retainer snaps in place. 7. Push down on the redundant latch (1) until it is fully engaged and snapped into position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 3453 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure (Ignition ON, engine OFF)............................................................................................. ..............................................345-414 kPa (50-60 psi) fuel pressure should not decrease more than 34 kPa (5 psi) in 1 minute Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3458 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3459 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of the flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Fuel Pressure Gage * J 37287 - Fuel Line Shut-Off Adapters Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition OFF, all accessories OFF, install the CH 48027 - Gage. Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Gage Installation and Removal). 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3460 ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Install the J 37287 - Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 Shut-Off Adapters. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Operate the vehicle within the Conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gage. The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect and repair the items listed below. If all items test normal, replace the fuel sender. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (See: Fuel Return Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (See: Service and Repair) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement Fuel Injection Fuel Rail Assembly Replacement Removal Procedure Note: An 8-digit identification number is located on the fuel rail. Refer to this model identification number if servicing or part replacement is required. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3468 4. Remove the positive crankcase ventilation (PCV) foul air hose (1). 5. Remove the engine wiring harness clip (1) from the ignition coil bracket stud (2). 6. Remove the engine wiring harness clip (1) from the ignition coil bracket stud (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3469 7. Disconnect the engine wiring harness electrical connector (2) from the throttle body. 8. Disconnect the engine wiring harness electrical connectors (1) from the fuel injectors. 9. Disconnect the engine wiring harness electrical connector (3) from the ignition coil harness. 10. Disconnect the engine wiring harness electrical connector (1) from the generator. 11. Disconnect the engine wiring harness electrical connector (3) from the evaporative emission (EVAP) canister purge solenoid valve. 12. Disconnect the engine wiring harness electrical connector (4) from the ignition coil harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3470 13. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors. 14. Remove the engine wiring harness bracket nut (1). 15. Remove the engine wiring harness bracket (2) from the stud and reposition the harness as needed. 16. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (See: Emission Control Systems/Evaporative Emissions System/Canister Purge Solenoid/Service and Repair). 17. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3471 18. Remove the fuel rail bolts (1). 19. Loosen but do not remove the fuel rail crossover pipe retainer clip screws. Caution: * Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. * Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. Note: Before removal, clean the fuel rail with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent. 20. Remove the fuel rail assembly (2). 21. Remove and discard the fuel injector lower O-ring seals (3). 22. If the fuel rail is not being replaced, proceed to the installation procedure. Disassembly Procedure 1. Remove the fuel injectors from the fuel rail. Refer to Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement). 2. Remove the service port cap and valve from the fuel rail. Assembly Procedure 1. Install the service port cap and valve to the fuel rail. 2. Install the fuel injectors to the fuel rail. Refer to Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3472 Warning The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns. 1. Lubricate NEW lower injector O-ring seals with clean engine oil. 2. Install the NEW O-ring seals (3) onto each injector. 3. Install the fuel rail (2) to the intake manifold. 4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel rail bolts (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the fuel rail bolts (1) and tighten to 10 Nm (89 lb in). 6. Tighten the fuel rail retainer clip screws to 3.8 Nm (34 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3473 7. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 8. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (See: Emission Control Systems/Evaporative Emissions System/Canister Purge Solenoid/Service and Repair). 9. Position the engine wiring harness as needed, and install the engine wiring harness bracket (2) to the stud. 10. Install the engine wiring harness bracket nut (1) and tighten to 9 Nm (80 lb in). 11. Connect the engine wiring harness electrical connectors (3) to the fuel injectors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3474 12. Connect the engine wiring harness electrical connector (4) to the ignition coil harness. 13. Connect the engine wiring harness electrical connector (3) to the EVAP canister purge solenoid valve. 14. Connect the engine wiring harness electrical connector (1) to the generator. 15. Connect the engine wiring harness electrical connector (3) to the ignition coil harness. 16. Connect the engine wiring harness electrical connectors (1) to the fuel injectors. 17. Connect the engine wiring harness electrical connector (2) to the throttle body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3475 18. Install the engine wiring harness clip (1) to the ignition coil bracket stud (2). 19. Install the engine wiring harness clip (1) to the ignition coil bracket stud (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3476 20. Install the PCV foul air hose (1). 21. Connect the engine wiring harness electrical connector (1) to the MAP sensor. 22. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 23. Install the fuel fill cap. 24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 25. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3477 Fuel Rail: Service and Repair Fuel Injection Fuel Rail Crossover Tube Replacement Fuel Injection Fuel Rail Crossover Tube Replacement Removal Procedure 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Remove the fuel rail crossover pipe retaining clip screws (1) and retainer clips (3). 3. Remove the crossover pipe (2) from the left and right hand fuel rails. 4. Remove and discard the crossover fuel pipe O-ring seals (4). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement > Page 3478 1. Lubricate the NEW fuel rail crossover pipe O-ring seals (4) with clean engine oil. 2. Install the NEW fuel rail crossover pipe O-ring seal (4) onto the crossover pipe (2). 3. Install the fuel rail crossover pipe (2) to the left and right hand fuel rails. 4. Install the fuel rail crossover pipe retainer clips (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the retaining clip screws for the fuel rail crossover pipe, always start the screws by hand. This will prevent stripping of the threads on the rail. 5. Install the fuel rail retainer clip screws (1). Tighten the screws to 3.8 Nm (34 lb in). 6. Install the fuel fill cap. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 8. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn OFF the ignition OFF for 10 seconds. 3. Turn ON the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Technician Safety Information). Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution). 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 3. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel pipe bracket nut (3) from the transmission stud. 6. Remove the fuel pipe bracket from the stud. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Page 3482 7. Disconnect the fuel tank fuel feed line quick connect fitting (4) from the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Disconnect the EVAP line quick connect fitting (1) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 9. Remove the chassis fuel feed and EVAP line bracket bolt (2). 10. Lift the chassis fuel feed and EVAP line assembly (3) up in order the remove the bracket tab from the crossmember. 11. Remove the fuel feed and EVAP line clip (4) from the fuel line bracket. 12. Remove the fuel pipe bracket bolt (6). 13. Remove the fuel feed and EVAP pipe assembly (3) from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Page 3483 1. Install the fuel feed and EVAP pipe assembly (3) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the fuel pipe bracket (5) and install the bracket bolt (6). Tighten the bolt to 4.5 Nm (40 lb in). 3. Install the fuel feed and EVAP line clip (4) to the fuel line bracket. 4. Position the chassis fuel feed and EVAP line assembly (3) bracket tab to the crossmember. 5. Install the chassis fuel feed and EVAP line bracket bolt (2). Tighten the bolt to 10 Nm (89 lb in). 6. Connect the EVAP line quick connect fitting (1) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Page 3484 7. Connect the fuel tank fuel feed line quick connect fitting (4) to the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Install the fuel pipe bracket onto the stud. 9. Install the fuel pipe bracket nut (3) to the transmission stud. Tighten the nut to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 12. Connect the chassis EVAP line quick connect fitting (1) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis Removal Procedure Warning: Refer to Fuel and Evaporative Emission Pipe Warning (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Technician Safety Information). Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage Warnings/Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution). 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)). 2. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 3. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel pipe bracket nut (3) from the transmission stud. 6. Remove the fuel pipe bracket from the stud. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3488 7. Disconnect the fuel tank fuel feed line quick connect fitting (4) from the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Disconnect the EVAP line quick connect fitting (1) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 9. Remove the chassis fuel feed and EVAP line bracket bolt (2). 10. Lift the chassis fuel feed and EVAP line assembly (3) up in order the remove the bracket tab from the crossmember. 11. Remove the fuel feed and EVAP line clip (4) from the fuel line bracket. 12. Remove the fuel pipe bracket bolt (6). 13. Remove the fuel feed and EVAP pipe assembly (3) from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3489 1. Install the fuel feed and EVAP pipe assembly (3) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the fuel pipe bracket (5) and install the bracket bolt (6). Tighten the bolt to 4.5 Nm (40 lb in). 3. Install the fuel feed and EVAP line clip (4) to the fuel line bracket. 4. Position the chassis fuel feed and EVAP line assembly (3) bracket tab to the crossmember. 5. Install the chassis fuel feed and EVAP line bracket bolt (2). Tighten the bolt to 10 Nm (89 lb in). 6. Connect the EVAP line quick connect fitting (1) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3490 7. Connect the fuel tank fuel feed line quick connect fitting (4) to the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Install the fuel pipe bracket onto the stud. 9. Install the fuel pipe bracket nut (3) to the transmission stud. Tighten the nut to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 12. Connect the chassis EVAP line quick connect fitting (1) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement Removal Procedure 1. Partially drain the fuel tank below the level of the fuel fill tube. Refer to Fuel Tank Draining (See: Service and Repair). 2. Raise and support the vehicle, high enough to access the fuel fill hose through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle ( See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 4. Remove the fuel fill hose ground strap bolt. 5. Remove the ground strap from the frame. 6. Loosen the fuel fill hose clamp (2) at the fuel tank. 7. Disconnect the evaporative emission (EVAP) line (1) quick connect fitting from the fill tube vent line. Refer to Plastic Collar Quick Connect Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3495 Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Separate the fuel fill hose from the fuel tank. 9. Remove the fuel fill hose screws. 10. Remove the fuel fill hose from the vehicle. 11. Cap the open end of the fuel tank in order to prevent system contamination. Installation Procedure 1. Uncap the fuel tank. 2. Position the fuel fill hose to the fender. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fuel fill hose screws and tighten to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3496 4. Install the fuel fill hose to the fuel tank. 5. Connect the fuel tank EVAP line (1) quick connect fitting to the fill tube vent line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. Tighten the fuel fill hose clamp (2) at the fuel tank to 2.5 Nm (22 lb in). 7. Install the ground strap to the frame. Ensure that the anti rotation tab is inserted into the hole in the frame. 8. Install the fuel fill hose ground strap bolt and tighten to 9 Nm (80 lb in). 9. Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 10. Lower the vehicle. 11. Refill the fuel tank. 12. Install the fuel fill cap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement Removal Procedure 1. Open the fuel filler door. 2. Remove the fuel cap. 3. Remove the fuel filler hose. Refer to Fuel Tank Filler Hose Replacement (). 4. Remove the screws from the fuel filler pocket. 5. Remove the fuel filler pocket from the vehicle. Installation Procedure 1. Align the fuel filler pocket to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws to the fuel filler pocket and tighten to 10 Nm (89 lb in). 3. Install the fuel filler hose. Refer to Fuel Tank Filler Hose Replacement (). 4. Install the fuel cap. 5. Close the fuel filler door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Tank Unit: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3509 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3510 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3511 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 3516 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3523 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3524 * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 6. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 10. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 13. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (V8) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (2.9L and 3.7L) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3525 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3531 Accelerator Pedal Position Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3532 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3533 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3534 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 3535 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3536 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3537 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor nuts. 3. Remove the APP sensor from the vehicle. Installation Procedure 1. Position the APP sensor over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3538 2. Install the APP sensor nuts. Tighten the APP sensor mounting nuts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector. 4. Inspect below the pedal for binding, to ensure full range of motion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3542 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2) from the air cleaner upper housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3543 Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor (2) to the air cleaner upper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1). Tighten the screws to 1.5 Nm (13 lb in). 3. Connect the engine wiring harness electrical connector to the MAF/IAT sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams Throttle Body: Diagrams Component Connector End Views Throttle Body Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures Throttle Body: Procedures Throttle Learn Throttle Learn Description The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure With Scan Tool - Reset Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * Ignition ON, engine OFF. * The vehicle speed sensor (VSS) is 0 km/h (0 mph). Without Scan Tool - Learn Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition 1 voltage is greater than 10 volts. Throttle Learn With Scan Tool - Reset Procedure 1. Ignition ON, engine OFF, with a scan tool, perform the Idle Learn Reset in Module Setup. 2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed. 3. Clear the DTCs and return to the diagnostic that referred you here. Without Scan Tool - Learn Procedure Important: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions). 1. Start and idle the engine in PARK for 3 minutes. 2. With a scan tool, monitor desired and actual RPM. 3. The ECM will start to learn the new idle cells and Desired RPM should start to decrease. 4. Ignition OFF for 60 seconds. 5. Start and idle the engine in PARK for 3 minutes. 6. After the 3 minute run time the engine should be idling normal. Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 7. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 3549 8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here. Throttle Body Cleaning Throttle Body Cleaning 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Warning Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle valve plate for deposits. You will need to open the throttle valve in order to inspect all surfaces. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM top engine cleaner, GM P/N 1052626 (Canadian P/N 993026) or ACDelco Carburetor Tune-Up Conditioner, P/N X66-P or an equivalent product. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 5. Perform the throttle learn procedure. Refer to Throttle Learn (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Throttle Learn). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 3550 Throttle Body: Removal and Replacement Throttle Body Assembly Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. Caution: DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the throttle body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 3551 3. Remove the throttle body bolts (538) and nuts (507). 4. Remove the throttle body (508). 5. Remove and discard the throttle body seal (509). Installation Procedure 1. Install a NEW throttle body gasket (509). 2. Install the throttle body (508). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the throttle body bolts (538) and nuts (507). Tighten the bolts/nuts to 10 Nm (89 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 3552 4. Connect the engine wiring harness electrical connector (2) to the throttle body. 5. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 6. Perform the throttle learn procedure. Refer to Throttle Learn (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Throttle Learn). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3560 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3561 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3565 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3568 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3569 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 3573 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. * Twist each spark plug 1/2 turn. * Pull only on the boot in order to remove the wire from each spark plug. 2. Remove the spark plug wire from the ignition coil. * Twist each spark plug boot 1/2 turn. * Pull only on the boot in order to remove the wires from the ignition coil. Installation Procedure 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the wires for proper installation: * Push sideways on each boot in order to inspect the seating. * Reinstall any loose boot. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Ignition Coil: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 3582 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 3583 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Ignition Coil: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 3589 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 3590 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3591 Ignition Coil: Diagrams Component Connector End Views Ignition Coil 1 (LH8) Ignition Coil 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3592 Ignition Coil 3 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3593 Ignition Coil 4 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3594 Ignition Coil 5 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3595 Ignition Coil 6 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3596 Ignition Coil 7 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3597 Ignition Coil 8 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3598 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3599 Ignition Coil: Service and Repair Ignition Coil Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the spark plug wire from the ignition coil. 3. Disconnect the ignition coil electrical connector. 4. Remove the ignition coil bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3600 5. Remove the ignition coil. Installation Procedure 1. Install the ignition coil. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition coil bolts. Tighten the bolts to 8 Nm (71 lb in). 3. Connect the ignition coil electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3601 4. Connect the spark plug wire to the ignition coil. 5. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3605 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3606 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3607 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3610 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3611 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3612 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Powertrain Component Views Engine - Front (LH8) 1 - Throttle Body 2 - Camshaft Position (CMP) Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3617 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3618 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Powertrain Component Views Engine - Right Side (LH8) (5.3L) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3622 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3625 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Motor Replacement (LLV/LLR) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Motor Replacement (LH8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3626 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding This vehicle has two different types of ignition lock cylinders based on what type of steering column the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder designs. Ignition Lock Cylinder The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side. Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into the case assembly (5). 1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3. The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install this tumbler in the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4 tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8. Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct key into the lock cylinder. All tumblers (1) should be flush with the housing of the lock cylinder. 9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM Super Lube GM P/N 12346241 or equivalent light lithium grease. 10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front face of the rotor. If the slide piece is installed incorrectly, the key cannot insert into the rotor due to no access to the ramp. 11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock cylinder housing. Ensure that the actuator lever is inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should pivot on the pin against spring tension. 12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side with the security plug (3) faces to the left of the key head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 3632 13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the center of the lock cylinder housing (1) and hold it. Insert the coded lock cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the housing. 15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward slightly. The key should be able to be removed and the lock cylinder should remain in the housing. 16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the lock cylinder housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 3633 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4. Remove the ignition lock cylinder case. Installation Procedure 1. Install the ignition lock cylinder case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition switch, a passlock relearn will be needed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining pin down. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 3634 5. Pull the ignition lock cylinder away from the steering column. Installation Procedure 1. Install the ignition lock cylinder by performing the following procedure: 1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until the retaining pin locks it in place. 2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Engine - Right Side (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3638 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3639 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (LH8) Knock Sensor (KS) 2 (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3640 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector from the KS (2). 3. Remove the KS retaining bolt. 4. Remove the KS (2) from the engine block. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3643 1. Install the KS (2) and the retaining bolt to the engine block, positioning the electrical terminals down. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector to the KS (2). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3644 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and support the vehicle only high enough to access the number 2 knock sensor (KS) through the wheelhouse. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (3) from the KS (1). 4. Remove the KS retaining bolt. 5. Remove the KS (1) from the engine block. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3645 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the KS (1) and the retaining bolt to the engine block, positioning the electrical terminals rearward. Tighten the KS bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to the KS (1). 3. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: Customer Interest Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 3654 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System - Runs Rough MIL/ON DTC P0300/P0306 > Page 3655 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System Runs Rough MIL/ON DTC P0300/P0306 Spark Plug: All Technical Service Bulletins Ignition System - Runs Rough MIL/ON DTC P0300/P0306 TECHNICAL Bulletin No.: 09-06-04-025A Date: December 20, 2010 Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300-P0306 Set, Engine Runs Rough (Inspect for Water Intrusion in Spark Plug Recess Area, Replace Spark Plug and Ignition Coil, Seal Ignition Coil Bolt Hole Vents and Seal Hood Air Grille) Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV or LL8 Please Refer to GWM/IMH Supercede: This bulletin is being revised to add an Important to the Hood Grille Modification section. Please discard Corporate Bulletin Number 09-06-04-025 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI. 1. Observe the Misfire Current Counters parameter with a scan tool, in order to determine the affected cylinder(s). 2. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 3. Disconnect the engine wiring harness electrical connectors from the affected ignition coil(s). Refer to Ignition Coil Replacement in SI. 4. Remove the ignition coil bolt(s) and ignition coil(s) from the camshaft cover. Refer to Ignition Coil Replacement in SI. Note If water is observed in ANY of the spark plug recess areas, then it will be necessary to apply Loctite(R) 565 PST Thread Sealant* to ALL of the ignition coil bolt hole vents and bolt threads. 5. Inspect for water intrusion in the spark plug recess areas. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 6. If any water is present, then remove the water from the spark plug recess areas with low pressure air. 7. Remove the affected spark plug(s) from the cylinder head. Refer to Spark Plug Replacement in SI. 8. Replace ONLY the affected spark plug(s) with new spark plug(s) as needed into the cylinder head. Refer to Spark Plug Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System Runs Rough MIL/ON DTC P0300/P0306 > Page 3661 9. Fill the bottom of the ignition coil bolt hole vent with Loctite(R) 565 PST Thread Sealant* as indicated in the illustration, and apply it to the ignition coil bolt threads also. 10. Replace ONLY the affected ignition coil(s) with new ignition coil(s) as needed. Refer to Ignition Coil Replacement in SI. 11. Connect the engine wiring harness electrical connectors to the ignition coil(s). Refer to Ignition Coil Replacement in SI. 12. Replace the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement in SI. 13. Clear the DTCs with a scan tool. Hood Grille Modification for HUMMER H3 Vehicles Only Important Use the Investigate Vehicle History link in Global Connect, to determine if Recall #10088A: Product Safety - Hood Louver Separation has been performed on the vehicle. If Recall #10088A has been performed on the vehicle, DO NOT perform the following hood grille modification. 1. Remove the hood air grille. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 2. Secure 3M(TM) Strip Calk(R), P/N 051135* around the outside perimeter of the integral retention clip (1) opening in the vehicle hood (all 4 sides of the rectangular slot). 3. Repeat this procedure for the remaining slots. 4. Install the hood air grille. Verify that it fits tightly against the hood. Refer to Hood Air Grille Replacement (H3) or Hood Air Grille Replacement (H3T) in SI. 5. Advise the customer to use care when washing the hood on the HUMMER vehicles. Extreme water pressure should not be directly applied to the edges of the hood air grille. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 09-06-04-025A > Dec > 10 > Ignition System Runs Rough MIL/ON DTC P0300/P0306 > Page 3662 from other sources. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3663 Spark Plug: Specifications Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3664 Spark Plug: Application and ID Ignition System Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3665 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1) - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess are of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3,4). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3666 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A looses center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3,4). Deposits on the electrodes (3,4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3,4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3667 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). 2. Loosen the spark plug 1-2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Specifications). 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the spark plug. Tighten the plug to 20 Nm (15 lb ft). 5. Install the spark plug wire. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3677 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3678 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3679 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3689 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3690 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3691 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3692 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3693 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3694 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3695 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3696 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3697 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3698 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3699 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3700 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3701 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3702 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3703 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3704 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3705 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3706 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3707 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3708 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3709 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3710 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3711 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3712 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3713 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3714 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3715 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3716 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3717 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3718 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3719 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3720 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3721 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3722 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3723 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3724 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3728 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3731 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3732 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3733 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3736 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3737 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3738 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3739 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3740 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3741 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3742 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3743 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3750 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3778 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3779 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3780 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3781 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3782 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3783 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3784 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3788 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3789 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3790 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3791 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3792 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3793 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3794 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3795 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3796 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3797 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3798 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3828 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3829 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3830 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3831 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3832 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3834 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3836 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3837 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3838 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3839 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3840 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3841 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3842 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3843 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3844 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3845 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3846 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3858 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3859 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3860 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3861 Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3898 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3899 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3902 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3903 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3904 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3908 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3909 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3910 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3911 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3927 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3928 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3937 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3958 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3959 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3960 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3964 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4039 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4040 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4041 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4042 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4043 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4044 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 6. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid retainer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4045 9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). 11. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Electric Motor Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Remove the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 4050 4. Remove the electric motor actuator. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation. 1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 4051 2. Install the electrical connector. 3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 4057 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 4058 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Inside the Transmission Components (M30) 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4064 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30) Description Location Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4068 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4069 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4070 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4071 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4072 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Sensor (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 4083 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position switch (1). 2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 4084 1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1), until the locking tabs (2) are fully engaged. 2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the following in order to adjust the clutch pedal position switch (1). 1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2. Depress the clutch pedal all the way to the floor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4089 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4090 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4091 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4092 PROM - Programmable Read Only Memory: Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4093 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4094 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 4095 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4105 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4106 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4107 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4118 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4119 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4120 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4123 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4124 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4125 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4173 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4175 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4216 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4286 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4287 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4288 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4289 Transmission/Transaxle/Service and Repair/Removal and Replacement). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4349 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4350 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4404 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4405 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4467 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4468 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4469 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4470 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4471 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4472 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 6. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid retainer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4473 9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 11. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Electric Motor Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Remove the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 4478 4. Remove the electric motor actuator. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation. 1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 4479 2. Install the electrical connector. 3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4488 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4489 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4490 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4669 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4670 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4671 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4849 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4850 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4851 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4852 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4853 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4854 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 6. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid retainer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4855 9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 11. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets Special Tools * J 25025-B Pump and Valve Body Alignment Pin Set * J 36850 Transjel Lubricant Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). Note: The 1-2 accumulator can be removed without removing the control valve assembly. 3. Remove the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair). 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2 accumulator cover assembly. 6. Disassemble the 1-2 accumulator. Refer to 1-2 Accumulator Disassemble (See: Service and Repair/Overhaul). 7. Remove the spacer plate support retaining bolts (77). Note: Use care not to drop the following items that will be removed along with the spacer plate: * The number 1 checkball * The 3-4 accumulator spring * The 3-4 accumulator pin Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4859 8. Remove the spacer plate support (53 or 113). Note: Do not reuse the bonded spacer plate. Replace with a NEW bonded spacer plate. 9. Remove the bonded valve body spacer plate (48), discard, do not reuse. 10. Remove the 3-4 accumulator piston (2). Note: Some models do not use a 3-4 accumulator spring. 11. Inspect the 3-4 accumulator spring for cracks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4860 12. Remove the 3-4 accumulator piston seal (45) from the 3-4 accumulator piston (44). 13. Inspect the 3-4 accumulator piston for the following defects: * Porosity * Cracks * Scoring * Nicks and scratches Installation Procedure 1. Install a new 3-4 accumulator piston seal (45) to the 3-4 accumulator piston (44). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4861 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850 . 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4862 5. Place the checkball (1) on the spacer plate in the location shown. 6. Place the 3-4 accumulator spring (2) on the spacer plate. 7. Install the J-25025-5 - guide pins into the case. Note: Do not reuse the bonded spacer plate. Replace with a NEW bonded spacer plate. 8. Place the bonded spacer plate on the case. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4863 9. Install the spacer plate support plate (53 or 113). 10. Install the spacer plate bolts (77). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Install the accumulator bolt (115), model dependent and tighten the accumulator bolt to 11 Nm (97 lb in). 12. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 13. Assemble the 1-2 accumulator. Refer to 1-2 Accumulator Assemble (See: Service and Repair/Overhaul). 14. Install the 1-2 accumulator. Refer to 1-2 Accumulator Installation (See: Service and Repair/Overhaul). 15. Remove the J 25025-B from the transmission case. 16. Install the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair). 17. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 18. Lower the vehicle. 19. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 20. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair Band Apply Servo: Service and Repair 2-4 Servo (5.3L) Special Tools J 29714-A Servo Cover Depressor Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 3. Remove the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side (LH8) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). 4. Remove the heat shield bolts (1). 5. Remove the heat shield (2). 6. Clean away all dirt and debris from the 2-4 servo cover area. 7. Remove a single transmission oil pan bolt. 8. Install the J 29714-A in place of the transmission oil pan bolt. 9. Tighten the bolt in order to compress the servo cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4867 10. Remove the servo cover retaining ring. 11. Remove the J 29714-A . 12. Remove the servo cover and the O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 13. Remove the 2-4 servo from the transmission. 14. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects. * Cracks * Scoring * Burrs and nicks 15. Disassemble the 2-4 servo if necessary. Refer to 2-4 Band Servo 2nd Apply Piston Disassemble (See: Service and Repair/Overhaul). 16. Clean and inspect the 2-4 servo. Refer to 2-4 Band Servo Piston Pin Length Check (See: Service and Repair/Overhaul). Installation Procedure 1. Assemble the 2-4 servo if previously disassembled. Refer to 2-4 Servo Assembly Installation (See: Service and Repair/Overhaul). 2. Lightly lubricate the seals with clean transmission fluid. 3. Install new seals on the servo pistons and the servo cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4868 4. Install the 2-4 servo assembly into the transmission. 5. Install the J 29714-A to the transmission oil pan flange. 6. Tighten the bolt in order to compress the servo cover. 7. Install the servo cover retaining ring. 8. Remove the J 29714-A . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the oil pan bolt and tighten to 11 Nm (97 lb in). 10. Install the heat shield (2). 11. Install the heat shield bolts (1) and tighten to 10 Nm (89 lb in). 12. Install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (LH8) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Left Side). 13. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4869 Shaft/Service and Repair/Front Propeller Shaft Replacement). 14. Lower the vehicle. 15. Fill the transmission to the proper level. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 16. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4878 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4888 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Page 4897 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Page 4898 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Transmission Fluid Filler Tube and Seal Replacement (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair Case Extension Assembly Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the transmission mount. Refer to Transmission Mount Replacement (2WD) (See: Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission Mount/Service and Repair). 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O-ring seal (3). Installation Procedure 1. Install a new case extension O-ring seal (3). 2. Install the case extension (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the case extension bolts (1) and tighten to 45 Nm (33 lb ft). 4. Install the transmission mount. Refer to Transmission Mount Replacement (2WD) (See: Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission Mount/Service and Repair). 5. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 4909 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID Pan Removal ......................................................................... ..................................................................................................................... 4.7 liters (5.0 qts) Overhaul .............................................................................................................................................. ................................................... 10.6 liters (11.0 qts) With 245 mm Torque Converter Dry Fill ......... .............................................................................................................................................................. ................................ 8.3 liters (8.8 qts) With 258 mm Torque Converter Dry Fill ................................ .............................................................................................................................................................. ......... 8.8 liters (9.3 qts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4912 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSAXLE FLUID DEXRON-VI Automatic Transmission Fluid. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4913 Fluid - A/T: Testing and Inspection Transmission Fluid Check This procedure checks the transmission fluid level, as well as the condition of the fluid itself. Caution: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Before checking the fluid level, perform the following: 1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 RPM for at least 1 minute. Slowly release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the appropriate check procedure. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Cold Check Procedure Note: * Use the cold check procedure only as a reference to determine if the transmission has enough fluid to be operated safely until a hot check procedure can be made. The hot check procedure is the most accurate method to check the fluid level. Perform the hot check procedure at the first opportunity. * Use this cold check procedure to check fluid level when the TFT is between 27-32°C (80-90°F). 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out again. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check line, add only enough fluid as necessary to bring the level into the COLD line. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the transmission reaches a normal operating temperature between 82-93°C (180-200°F). Hot Check Procedure Note: Use this procedure to check the transmission fluid level when the TFT is between 82-93°C (180-200°F). The hot check procedure is the most accurate method to check the fluid level. The hot check should be performed at the first opportunity in order to verify the cold check. The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick tip pointing down and check both sides of the dipstick. Read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the transmission temperature is between 82-93°C (180-200°F), add or drain fluid as necessary to bring the level into the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. Note: To assist in reaching the correct temperature range of 82-93°C (180-200°F), drive the vehicle in second gear at no more than 65 mph until the desired temperature is reached. 7. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Testing and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4914 Inspection/Component Tests and General Diagnostics/Fluid Leak Diagnosis). 8. If the fluid level is in the acceptable range, push the dipstick back into the dipstick tube all the way, and then flip the handle down to lock the dipstick in place. 9. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid was changed. Fluid Condition Inspection Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Engine Coolant/Water in Transmission). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4915 Fluid - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: Do not pull on the boot portion of the cable. 2. Complete the following in order to disconnect the range selector cable (3) from the transmission range selector lever ball stud: 1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever (1). 2. Pry the range selector cable end (5) away from the range selector lever (1). 3. Remove the bolts securing the transmission range selector cable bracket to the transmission. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4916 4. Position the transmission range selector cable bracket aside for clearance while lowering the pan. 5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to drain into the container. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4917 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for root cause diagnosis: * Bronze slivers indicating bushing wear * Clutch material * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces of the old gasket material must be removed. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4918 1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the container used to catch the used transmission fluid from under the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4919 7. Position the transmission range selector cable bracket to the transmission. 8. Install the transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment (5.3L) (See: Shift Linkage/Shift Cable/Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Shift Linkage/Shift Cable/Adjustments). 10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) and Fluid Capacity Specifications (See: Specifications/Capacity Specifications). 12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: Do not pull on the boot portion of the cable. 2. Complete the following in order to disconnect the range selector cable (3) from the transmission range selector lever ball stud: 1. Insert a flat-bladed tool between the range selector cable end (5) and the range selector lever (1). 2. Pry the range selector cable end (5) away from the range selector lever (1). 3. Remove the bolts securing the transmission range selector cable bracket to the transmission. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4923 4. Position the transmission range selector cable bracket aside for clearance while lowering the pan. 5. Position an appropriate container under the transmission oil pan. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan, allow the transmission fluid to drain into the container. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4924 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 12. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. The filter may contain the following evidence for root cause diagnosis: * Bronze slivers indicating bushing wear * Clutch material * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. All traces of the old gasket material must be removed. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4925 1. Coat the new filter seal with clean automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts and tighten alternately and evenly to 16 Nm (12 lb ft). 6. Remove the container used to catch the used transmission fluid from under the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4926 7. Position the transmission range selector cable bracket to the transmission. 8. Install the transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 9. Adjust the automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment (5.3L) (See: Shift Linkage/Shift Cable/Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Shift Linkage/Shift Cable/Adjustments). 10. Lower the vehicle. 11. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) and Fluid Capacity Specifications (See: Specifications/Capacity Specifications). 12. Check the COLD fluid level reading for initial fill only. 13. Inspect the oil pan gasket for leaks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair) 3. Disconnect the transmission fluid cooler lines (3) from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 4. Remove the transmission fluid cooler lines from the retainer located on the radiator. 5. Remove the transmission fluid cooler lines from the retainer located on the right side of the engine. 6. Support the transmission with a transmission jack. 7. Remove the transmission support. Refer to Transmission Support Crossmember Replacement (2WD) (See: Body and Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember Replacement)Transmission Support Crossmember Replacement (4WD) (See: Body and Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember Replacement). 8. Remove the front exhaust pipe assembly. Refer to Catalytic Converter Replacement (LLV/LLR w/2WD) ()Catalytic Converter Replacement (LLV/LLR - w/4WD) (). 9. Carefully lower the transmission to gain access to the transmission fluid cooler line fittings. 10. Disconnect the transmission fluid cooler lines (2) from the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 11. Remove the transmission fluid cooler lines (1) from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4931 Caution: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation. 1. Install the transmission fluid cooler lines (1) to the vehicle. 2. Install the transmission fluid cooler lines (2) to the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 3. Raise the transmission into position. 4. Install the front exhaust pipe assembly. Refer to Catalytic Converter Replacement (LLV/LLR - w/2WD) ()Catalytic Converter Replacement (LLV/LLR - w/4WD) (). 5. Install the transmission support. Refer to Transmission Support Crossmember Replacement (2WD) (See: Body and Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember Replacement)Transmission Support Crossmember Replacement (4WD) (See: Body and Frame/Frame/Cross-Member/Service and Repair/Transmission Support Crossmember Replacement). 6. Remove the transmission jack. 7. Install the clip that holds the transmission fluid cooler lines together. 8. Install the transmission fluid cooler lines to the right side of the engine. 9. Install the transmission fluid cooler line to the retainer located on the radiator. 10. Install the transmission fluid cooler lines (3) to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 11. Install engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair) 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4932 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4933 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4934 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4935 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade INFORMATION Bulletin No.: 08-07-30-040B Date: May 05, 2009 Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60 Automatic Transmission Oil Pan Magnet Upgrade Models: 2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5, ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is 4L60, M32 is 4L65, M70 is 4L70) Attention: Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer concern requires it. .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A (Section 07 - Transmission/Transaxle). .............................................................................................................................................................. .................................................................................. A new transmission oil pan magnet, P/N 29535617, was released for service. The current square transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given current the PCS electromagnet is stronger, causing the line pressure to be less than needed. When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given current at the PCS or the transmission oil pan was removed (for either normal maintenance or warranty service), only then should the transmission oil pan magnet be upgraded. 1. Remove and discard the original square transmission oil pan magnet and install a new one in the current location (See graphics below for the correct application). 2. Install the second new transmission oil pan magnet in the following location as shown in the illustration. 4T40 & 4T45 4T65E Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 4940 Note Only on 4T65E, the second magnet (left) should be attached to the transmission filter. If the magnet is attached in any other location, it may cause interference (refer to graphic above). 4L60 Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 4941 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Inside the Transmission Components (M30) 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4945 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30) Description Location Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Diagrams > Page 4957 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Diagrams > Page 4958 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4967 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4973 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4974 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4975 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4976 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Manual Shift Shaft Seal Replacement Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement Special Tools * J 43911 Selector Shaft Seal Remover * J 43909 Selector Shaft Seal Installer Removal Procedure 1. Disconnect the range selector lever cable and lever from the manual shaft. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the bore until it is seated at the bottom of the bore. 4. Connect the range selector lever cable and lever to the manual shaft. 5. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Manual Shift Shaft Seal Replacement > Page 4979 Seals and Gaskets: Service and Repair Propeller Shaft Front Slip Yoke Oil Seal Replacement Propeller Shaft Front Slip Yoke Oil Seal Replacement Tools Required * J 21426 Extension Housing Seal Installer * J 39440 Extension Housing Seal Installer (Booted Seal) * J 36850 Transjel Lubricant Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the vehicle. 3. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Refer to Case Extension Assembly Replacement (See: Extension Housing/Service and Repair). Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Manual Shift Shaft Seal Replacement > Page 4980 Note: If installing a slip yoke (booted) type seal (34), position the drain hole (1) toward the bottom of the transmission within the area shown 2. Use the J 21426 for a standard seal or J 39440 for a booted type seal with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Inside the Transmission Components (M30) 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4985 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30) Description Location Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4989 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4990 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4991 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4992 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4993 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5004 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5005 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5006 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5185 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5186 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5187 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair Shift Lever Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Disengage the shift lever seal (2) from the steering column trim covers (1) and slide it up the shift lever (4). 3. Remove the shift lever bolt (3) from the shift lever (4). 4. Remove the shift lever with the shift lever seal from the steering column. 5. Transfer any parts as needed. Installation Procedure 1. Install the shift lever with the shift lever seal to the steering column. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the shift lever bolt (3). Tighten the bolt to 20 Nm (15 lb ft). 3. Align and secure the shift lever seal (2) to the steering column trim covers (1). 4. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Range Selector Lever Cable Adjustment (5.3L) Adjustment Procedure 1. Ensure that the shift control is in the park (P) position. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Ensure that the range selector cable is not restricted. 4. Pull back the plastic cover (1) on the center connector. 5. Pull up on the center tabs of the lock button (2). Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the shift cable end (2) during this procedure. 6. Release the shift cable end (2) and allow the spring to tension/adjust the shift cable system. 7. Pull the cover (3) on the shift cable end (1) back. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 5195 8. Push the lock button (2) down to engage the locking teeth on the shift cable end (1). 9. Release the cover (1). 10. Verify the cover (1) conceals the lock (2). 11. If the cover (1) does not conceal the lock (2), the shift cable must be readjusted. 12. Lower the vehicle. 13. Check the vehicle for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement Shift Cable: Service and Repair Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement (5.3L) Note: The range selector cable can be disassembled and removed as two independent sections when removal of the complete cable is not necessary, or the cable can remain together and be removed as one piece not requiring disassembly of the cable. Disassembling Cable 1. Set the parking brake. 2. Ensure that the shift control lever is in the park (P) position. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Pull back the spring loaded cover (2) to expose the cable adjustment lock (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5198 5. Lift the cable adjustment lock (3) up to unlock both halves of the range selector cable (1, 4). 6. Rotate the range selector cable to expose the retaining clip (5). It may be necessary to pull the transaxle end of the range selector cable (4) out of the shift control end of the range selector cable (1) to fully expose the retaining clip (5). 7. Remove the retaining clip (2) from the range selector cable (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5199 8. Separate the shift control end of the cable (1) from the transmission end of the cable (3). Cable Removal - Transmission End 1. Remove the range selector cable retainers (2) from the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5200 2. Remove the heat shield bolts (1). 3. Remove the heat shield (2). Note: Do not pull on the boot portion of the cable. 4. Disconnect the range selector cable end (3) from the range selector lever. 5. Remove the retainer (1) from the range selector cable (2). 6. Push the range selector cable locking tabs (2) inward toward each other to release the cable from the bracket. Cable Removal - Shift Control End Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5201 1. Push the cable grommet (2) and cable (1) up through the floor panel. 2. Lower the vehicle. 3. Remove the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Pull the drivers side carpet up, enough to access the range selector cable. 5. Disconnect the range selector cable retainer (1) from the lower dash panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5202 6. Complete the following in order to disconnect the range selector cable (4) from the transmission range selector lever ball stud (1). 1. Insert a flat bladed tool between the range selector cable end (2) and the range selector lever. 2. Pry the range selector cable end (2) away from the range selector lever. 7. Remove the retainer (3) from the range selector cable (4). 8. Push the range selector cable locking tabs inward toward each other to release from the steering column bracket (5). 9. Remove the range selector cable (4) from the vehicle. Cable Installation - Shift Control End 1. Install the range selector cable (4) to the steering column bracket (5). 2. Install the retainer (3) to the range selector cable (4). 3. Push the range selector cable end (2) onto the range selector lever ball stud (1) to secure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5203 4. Connect the range selector cable retainer (2) to the lower dash panel (1). 5. Push the range selector cable down through the floor panel (2) and seat the cable grommet (1). 6. Reposition the drivers side carpet to the floor panel. 7. Inspect below the accelerator pedal for binding, to ensure full range of motion. 8. Install the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Cable Installation - Transaxle End 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: Ensure the range selector cable is routed exactly as originally positioned in the vehicle to avoid coming into contact with potential hazards such as hot, sharp, and moving objects. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5204 2. Install the range selector cable (2) to the range selector cable bracket. Ensure the range selector cable retaining tabs fully engage the range selector cable bracket. 3. Install the retainer (1) to the range selector cable (2). 4. Connect the range selector cable end (3) to the transaxle range switch lever. 5. Install the heat shield (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the heat shield bolts (1) and tighten to 10 Nm (89 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5205 7. Install the range selector cable retainers (2) to the frame. Assembling Cable 1. Install the cable retaining clip (2). 2. Push the transaxle end of the range selector cable (4) into the shift control end of the range selector cable (1) until the cable retaining clip (5) is fully locked into the range selector cable groove (3). 3. Ensure that the shift control lever and the transaxle range select lever are both in the park (P) position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5206 4. Ensure the transaxle cable end (4) is not being held and that the spring is allowed to tension the cable. 5. Depress the cable adjustment lock (3) in order to lock both halves of the range selector cable (1, 4). 6. Release the spring loaded cover (2) allowing it to cover the cable adjustment lock. 7. Adjust the automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment (5.3L) (See: Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Adjustments). 8. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5207 Shift Cable: Service and Repair Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement (5.3L) Removal Procedure 1. Ensure the vehicle is in the PARK position. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the transmission vent hose retainer (4) from the transmission range selector cable bracket. 4. Remove the heat shield bolts (1). 5. Remove the heat shield (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5208 Note: Do not pull on the boot portion of the cable. 6. Disconnect the range selector cable end (3) from the range selector lever. 7. Remove the retainer (1) from the range selector cable (2). 8. Push the range selector cable locking tabs (2) inward toward each other to release the cable from the bracket. 9. Remove the bolts securing the transmission range selector cable bracket to the transmission. 10. Remove the transmission range selector cable bracket from the transmission. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5209 1. Position the transmission range selector cable bracket to the transmission. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission range selector cable bracket bolts and tighten to 25 Nm (18 lb ft). 3. Install the range selector cable (2) to the range selector cable bracket. Ensure the range selector cable retaining tabs fully engage the range selector cable bracket. 4. Install the retainer (1) to the range selector cable (2). 5. Connect the range selector cable end (3) to the transaxle range switch lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5210 6. Install the heat shield (2). 7. Install the heat shield bolts (1) and tighten to 10 Nm (89 lb in). 8. Connect the transmission vent hose retainer (4) to the transmission range selector cable bracket. 9. Adjust the automatic transmission range selector cable. Refer to Range Selector Lever Cable Adjustment (5.3L) (See: Adjustments)Range Selector Lever Cable Adjustment (2.9L and 3.7L) (See: Adjustments). 10. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 5215 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Service and Repair Torque Converter Check Valve: Service and Repair Torque Converter Clutch Valve and Spring Replacement Removal Procedure 1. Remove the transmission filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 2. Disconnect the torque converter clutch (TCC) pulse width modulation (PWM) solenoid electrical connector. 3. Remove the TCC PWM solenoid retainer. 4. Remove the TCC PWM solenoid in order to access the TCC control solenoid bolts. 5. Disconnect the TCC control solenoid connector. 6. Remove the TCC control solenoid retaining bolts. 7. Remove the TCC control solenoid. Warning Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 8. Remove the TCC valve retainer ring (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Service and Repair > Page 5219 9. Remove the following parts: * The valve bore plug * The TCC valve * The TCC valve spring(s) Installation Procedure Note: * Clean and inspect the TCC solenoid O-ring for cuts, nicks, and damage. Replace if necessary. * Inspect the TCC bore for sediment and debris. Flush the bore if necessary. * Clean and inspect the TCC valve for binding, scoring, and damage. * Inspect the TCC spring for cracks and deformed or broken coils. 1. Install the following parts: * The TCC valve spring * The TCC valve * The valve bore plug 2. Install the TCC valve retainer ring (1). 3. Install the TCC control solenoid. 4. Install the TCC control solenoid retaining bolts and tighten to 8-14 Nm (71-124 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Service and Repair > Page 5220 5. Connect the TCC control solenoid connector. 6. Install the TCC PWM solenoid. 7. Install the TCC PWM solenoid retainer. 8. Connect the TCC PWM Solenoid electrical connector. 9. Install the transmission filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5226 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5398 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5399 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5400 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5401 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5402 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5403 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 6. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid retainer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5404 9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 11. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5409 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5410 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5411 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5412 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Mount Replacement (2WD) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission jack. 3. Remove the 2 nuts securing the transmission mount to the transmission support. 4. Raise the transmission off of the transmission support. 5. Remove the transmission mount bolts (4). 6. Remove the transmission mount (3). 7. Remove the transmission mount spacer bolts (1). 8. Remove the transmission mount spacer (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 5416 Installation Procedure 1. Install the transmission mount spacer (2). 2. Install the transmission mount spacer bolts (1). 3. Install the transmission mount (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolts (4) and tighten to 55 Nm (41 lb ft). 5. Lower the transmission and install the 2 nuts securing the transmission mount to the transmission support. Tighten the nuts to 57 Nm (42 lb ft). 6. Remove the transmission jack. 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5420 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5421 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5422 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5423 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5424 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair Transmission Pressure Test Port: Service and Repair Automatic Transmission Fluid Pressure Test Hole Plug Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the oil pressure test plug. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install an oil pressure test plug and tighten to 8 Nm (71 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair > Page 5428 2. Check the transmission fluid level, fill if necessary. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips Valve Body: Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 5439 Valve Body: Technical Service Bulletins A/T - Production Changes INFORMATION Bulletin No.: 08-07-30-041 Date: September 04, 2008 Subject: Information On 2009 M30 4L60E, M32 4L65E and M70 4L70E HYDRA-MATIC(R) RWD Four Speed Automatic Transmission Controls Product Update Models: 2009 Chevrolet Avalanche, Colorado, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer SS 2009 GMC Canyon, Envoy, Envoy Denali, Savana, Sierra, Yukon 2009 Saab 9-7X Models Equipped with HYDRA-MATIC(R) 4L60E, 4L65E, 4L70E Four Speed RWD Automatic Transmission (RPOs M30, M32, M70) For the 2009 model year, there are several controls changes to the 4L60E, 4L65E and 4L70E. The valve body casting has been changed and will not back service due to the removal of the components shown above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 5440 1. A new Internal Mode Switch (IMS) has been added (2). The PSM has been deleted. ^ Do not reuse the roll pin that retains the IMS (2) to the manual shaft (3). ^ Do not remove the "C" clip from the IMS (2). This will damage the part. 2. The manual shaft (3) has been redesigned to accommodate the IMS (2). 3. The actuator rod (1) is a new design and will back service. It has a flat on the rod to accommodate the IMS (2). The wiring harness has been changed and now has the temperature sensor (2) in the harness with a gray connector. Both the 20-way connector (1) and the 6-pin connector for the IMS are now blue in color (3). The new DTCs shown above have been added for the IMS. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5441 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5442 Valve Body: Service and Repair Control Valve Body Replacement Removal Procedure 1. Remove the fluid level indicator. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the oil pan, gasket, and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 4. Disconnect all the internal wiring harness electrical connectors from the electrical connectors (1-6) components. 5. Remove the torque converter clutch (TCC) pulse width modulation (PWM) solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5443 7. Remove the TCC solenoid retaining bolts (68). 8. Remove the TCC solenoid (with O-ring seal) and wiring harness (66) from the control valve body. 9. Reposition the harness to the side of the transmission case. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5444 10. Remove the manual detent spring bolt (64) and the spring assembly (63). 11. Remove all valve body bolts (59, 62, 120). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5445 12. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link is installed properly to the inside detent lever and the manual valve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5446 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. 5. Install the 12 valve body bolts (62), 2 bolts (59) and 3 bolts (120) that are shown only. 6. Finger tighten the bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5447 7. Install the transmission wiring harness on the valve body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the TCC solenoid valve and bolts (68). Tighten the bolts to 814 Nm (610 lb ft). Caution: Do not over-tighten the bolts. Over-tightening the bolts will distort the valve bores. Begin tightening from the center of the valve body tighten the bolts in a outward direction. 9. Inspect the ensure all of the valve body bolts are in the correct location. Each bolt number refers to a specific size, as indicated in the following list: * 59 M6 x 1.0 x 35.0 (Qty: 2) * 62 M6 x 1.0 x 47.5 (Qty: 12) * 120 M6 x 1.0 x 54.4 (Qty: 3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5448 10. Tighten the bolts from the center of the valve body working your way out in a spiral pattern to the outside edge. Tighten the bolts to 814 Nm (610 lb ft). 11. Install the TCC PWM solenoid valve (396) and the solenoid retainer (395). 12. Snap the wiring harness in place on the valve body bolts. Ensure the harness loom tab is located under the transmission fluid pressure (TFP) switch. 13. Install the wiring connectors to the electrical components (1-6) as indicated in the following list: 1. The manual shift detent lever with shaft position switch assembly 2. The 1-2 shift solenoid 3. The 2-3 shift solenoid 4. The pressure control solenoid (PCS) 5. The TCC PWM solenoid 6. The input speed sensor (ISS) 14. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Service and Repair/Removal and Replacement). 15. Lower the vehicle. 16. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5449 17. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair Clutch Assembly Replacement Special Tools J 36660-A Torque Angle Meter Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). 2. Remove the clutch pressure plate bolts (1). Discard the bolts. 3. Remove the clutch pressure plate (2) and driven disc (3) from the dowel pins (4) on the flywheel (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 5454 1. Install the clutch pressure plate (2) and driven plate (3) to the dowel pins (4) on the flywheel (5). 2. Install the clutch pressure plate bolts (1) finger tight. 3. Use the Snap-On A145 Clutch Aligner Set, or equivalent, to align the clutch driven plate (3) to the clutch pilot bearing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the NEW clutch pressure plate bolts in the sequence shown. 1. Tighten the clutch pressure plate bolts in sequence to 20 Nm (15 lb ft). 2. Use the J 36660-A in order to tighten the clutch pressure plate bolts in sequence an additional 45 degrees. 5. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement Tools Required J 42371 Hydraulic Clutch Line Separator Removal Procedure Important: A new retainer (3) is required after removal. 1. Complete the following in order to disengage the retainer (3) from the clutch pedal pin. 1. Insert a flat bladed tool (4) between the clutch master cylinder push rod (1) and the clutch pedal (2). 2. Pry the clutch master cylinder push rod (1) away from the clutch pedal assembly (2). Discard the retainer (3). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 5462 3. Using the J 42371 , push back the white plastic sleeve on the quick connect in order to separate the hydraulic clutch hose from the clutch actuator quick connect. It is not necessary to plug the lower hose end or slave cylinder fitting as they are equipped with check valves, only minimal fluid loss may be experienced. 4. Disconnect the clutch hydraulic hose retainer from the inner fender. 5. Lower the vehicle. 6. Rotate the clutch master cylinder clockwise 1/8 turn. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 5463 7. Remove the clutch master cylinder with hydraulic hose from the cowl. Installation Procedure 1. Route the clutch hydraulic hose with master cylinder under the brake booster. 2. With the clutch fluid reservoir cap at the 1:30 position. Insert the clutch master cylinder into the cowl. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 5464 3. Rotate the clutch master cylinder counter clockwise 1/8 turn until fully seated. The clutch fluid reservoir cap will be vertical at the 12:00 position when the clutch master cylinder is properly installed. 4. Raise the vehicle. Important: Ensure the clutch hydraulic hose does not come in contact with any sharp or potentially hot surfaces. 5. Push the clutch hydraulic hose quick connect fitting (2) into the clutch slave cylinder, until a "click" is heard. 6. Tug gently on the clutch hydraulic hose to ensure proper retention into the clutch slave cylinder. 7. Connect the clutch hydraulic hose retainer to the inner fender. 8. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 5465 9. Insert a new retainer (3) into the clutch master cylinder push rod (1). 10. Push the clutch master cylinder push rod (1) onto the clutch pedal pin to secure. 11. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control Release Switch Adjustment (See: Cruise Control/Clutch Switch/Adjustments). 12. Adjust the clutch pedal position switch. Refer to Clutch Pedal Position Switch Replacement (See: Clutch Pedal Position Sensor / Switch/Service and Repair). 13. Bleed the clutch hydraulic system, only if necessary. Refer to Hydraulic Clutch Bleeding (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). 2. Remove the 2 clutch actuator cylinder bolts (3). 3. Remove the clutch actuator cylinder (1) from the input shaft bearing retainer (2). Installation Procedure 1. Position the clutch actuator cylinder (1) to the input shaft bearing retainer (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 5469 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 clutch actuator cylinder bolts (3). Tighten the clutch actuator cylinder bolts to 8 Nm (71 lb in). 3. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Disconnect the electrical connectors (2, 4) from the following components: * The clutch pedal position switch (1) * The cruise control release switch (3) Note: A new retainer (3) is required after removal. 2. Complete the following in order to disengage the retainer (3) from the clutch pedal pin. 1. Insert a flat-bladed tool (4) between the clutch master cylinder push rod (1) and the clutch pedal (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 5473 2. Pry the clutch master cylinder push rod (1) away from the clutch pedal assembly (2). Discard the retainer (3). 3. Remove the 4 nuts securing the clutch pedal assembly to the cowl. 4. Remove the clutch pedal assembly from the vehicle. Installation Procedure 1. Position the clutch pedal assembly over the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal assembly nuts and tighten to 20 Nm (15 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 5474 3. Insert a new retainer (3) into the clutch master cylinder push rod (1). 4. Push the clutch master cylinder push rod (1) onto the clutch pedal pin to secure. 5. Connect the electrical connectors (2, 4) to the following components: * The clutch pedal position switch (1) * The cruise control release switch (3) 6. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control Release Switch Adjustment (See: Cruise Control/Clutch Switch/Adjustments). 7. Adjust the clutch pedal position switch. Refer to Clutch Pedal Position Switch Replacement (See: Clutch Pedal Position Sensor / Switch/Service and Repair). 8. Check for proper clutch pedal movement and operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Sensor (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5478 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position switch (1). 2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5479 1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1), until the locking tabs (2) are fully engaged. 2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the following in order to adjust the clutch pedal position switch (1). 1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2. Depress the clutch pedal all the way to the floor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Clutch Switch: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 5483 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 5484 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 5485 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 5486 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair Clutch Release Bearing Replacement Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). 2. Pull the clutch actuator cylinder release bearing (2) from the clutch actuator cylinder dust cover (1). Installation Procedure Important: Do not allow the release bearing to become damaged, replace if dropped or damaged. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Page 5490 1. Install the clutch actuator cylinder release bearing (2) over the clutch actuator cylinder dust cover (1). 2. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Clutch Pilot Bearing Replacement Special Tools * J 43276 Clutch Pilot Bearing Remover * J 45949 Pilot Bearing and Flywheel Locator Installer Removal Procedure Caution: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so causes damage to the J 43276-1 tool body. 1. Remove the flywheel. Refer to Engine Flywheel Replacement (with Automatic Transmission) ()Engine Flywheel Replacement (with Manual Transmission) () for the 2.9L engine or Engine Flywheel Replacement (with Manual Transmission) ()Engine Flywheel Replacement (with Automatic Transmission) () for the 3.7L engine. 2. Using the J 43276 perform the following in order to remove the clutch pilot bearing: 1. Install the J 43276-1 into the clutch pilot bearing. 2. Using a wrench, secure the J 43276-1. 3. Insert the J 43276-2 into the J 43276-1. 4. Rotate the J 43276-2 clockwise into the J 43276-1 until the clutch pilot bearing is completely removed from the crankshaft. 5. Rotate the J 43276-2 counterclockwise to remove the J 43276-2 from the J 43276-1. 6. Remove the J 43276-1 from the tool body. 3. Discard the old clutch pilot bearing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 5494 1. Install the J 45949 (3) into the clutch pilot bearing (1). 2. Install the clutch pilot bearing (1) into the crankshaft (2). The J 45949 (3) will install the pilot bearing (1) to the proper depth of 11.6 mm (0.457 in) (a). 3. Remove the J 45949 (3). 4. Install the flywheel. Refer to Engine Flywheel Replacement (with Automatic Transmission) ()Engine Flywheel Replacement (with Manual Transmission) () for the 2.9L engine or Engine Flywheel Replacement (with Manual Transmission) ()Engine Flywheel Replacement (with Automatic Transmission) () for the 3.7L engine. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications PRESSURE PLATE clutch pressure plate bolts in sequence to........................................................................................... .............................................................20 Nm (15 lb ft) clutch pressure plate bolts in sequence an a dditional............................................................................................................................................... 45 degrees Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 5498 Pressure Plate: Service and Repair Clutch Assembly Replacement Special Tools J 36660-A Torque Angle Meter Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). 2. Remove the clutch pressure plate bolts (1). Discard the bolts. 3. Remove the clutch pressure plate (2) and driven disc (3) from the dowel pins (4) on the flywheel (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 5499 1. Install the clutch pressure plate (2) and driven plate (3) to the dowel pins (4) on the flywheel (5). 2. Install the clutch pressure plate bolts (1) finger tight. 3. Use the Snap-On A145 Clutch Aligner Set, or equivalent, to align the clutch driven plate (3) to the clutch pilot bearing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the NEW clutch pressure plate bolts in the sequence shown. 1. Tighten the clutch pressure plate bolts in sequence to 20 Nm (15 lb ft). 2. Use the J 36660-A in order to tighten the clutch pressure plate bolts in sequence an additional 45 degrees. 5. Install the transmission. Refer to Transmission Replacement (4WD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement)Transmission Replacement (RWD) (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information INFORMATION Bulletin No.: 07-07-30-010B Date: June 19, 2009 Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using TIS Software Models: 2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models) 2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section 07 - Transmission/Transaxle). Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool platform and software will be required for use with all GM Global Architecture (Global A) vehicles beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R) communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number 09-00-89-019 (Introduction of New Global Diagnostic System (GDS)). This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and upload it to a computer. The procedure is written for an automatic transmission data snapshot on a Saturn AURA, but is similar for all applications. This procedure is written with the assumption the user has a basic understanding of how to use a Tech 2(R) already. Capturing a Snapshot of the Vehicle Data Stream 1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen. 3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the scan tool's display. Bolded selections are vehicle specific. - Select "2007" - Select "Passenger Car (F0)" - Select "Saturn" Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5504 - Select "Z" - Select "Aura" - Select "Powertrain" - Select "3.6L LY7" - Select "Transmission" - Select "Transmission Data" 5. From the application menu, select F3: Snapshot. - Choose trigger type and trigger point, as described above. - It is preferred to trigger on "Any Code" (F1) - If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on the next screen. - Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the events before and after the code sets. 6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going to record for live viewing. - When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1 and F5) are selected. - If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key to actually record data. Otherwise, it will automatically start recording when a DTC is set. - Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1 minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is selected). Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third snapshot is requested, the first snapshot will be overwritten. 7. When the snap shot data has been recorded, exit to the Main Menu, then power down and disconnect the Tech 2(R) from the vehicle. Uploading and Sending a Snapshot via TIS2WEB Figure 8 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5505 Figure 9 1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen just like the TIS 2000 procedure described above. Figure 10 3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure 10. Make sure the Tech 2(R) is connected to the computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech 2(R) should start blinking and a line will start scrolling across the screen indicating it is communicating with your computer. Figure 11 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5506 4. Once communication is established and you select the file you want to upload, you will see a screen similar to below. You can email the file directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail" as shown in Figure 11. Figure 12 5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill in the information as requested and then click send. Include the VIN in the subject line. 6. After all the information is entered, hit the send button. After sending the file, you will receive a confirmation box letting you know the e-mail was sent successfully. 7. It is recommended to now save the file to your computer using the same procedure as if you were using TIS 2000 in case your recipient doesn't receive your email with the snapshot data. Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is no way to access your sent mail in TIS2WEB like a regular e-mail program. Sending a Snapshot to GM TAC Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5507 During your call with GM TAC on a current case, you may be advised to send a copy of the Tech 2(R) or VDR Snapshot Data to the TAC e-mail box. U.S. Dealers - send to e-mail box [email protected] Canadian Dealers - send to e-mail box [email protected] Please complete the following: - Be sure to review the procedures listed above for uploading and sending a Snapshot via TIS2WEB. - If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink Website in the articles (December 2002, December 2003, July 2004 and January 2006). - Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email can not be processed and will be deleted. Please send only REQUESTED Snapshot Data to the TAC e-mail box. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5508 Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine Crankcase and Subsystems Flushing Info. INFORMATION Bulletin No.: 04-06-01-029E Date: April 29, 2010 Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM Simplified Maintenance Schedule to Enhance Customer Service Experience Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add information about the proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D (Section 06 - Engine/Propulsion System). An Overview of Proper Vehicle Service General Motors is aware that some companies are marketing tools and equipment to support a subsystem flushing procedures. These dedicated machines are in addition to many engine oil, cooling system, fuel system, A/C, transmission flush and steering system additives available to the consumer. GM Vehicles under normal usage do not require any additional procedures or additives beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are designed to aid and accelerate the process of fluid changing with these flushing machines. Engine Crankcase Flushing General Motors Corporation does not endorse or recommend engine crankcase flushing for any of its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing indicate incompatibility with GM engine components and the potential for damage to some engine seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT COVERED under the terms of the New Vehicle Warranty. GM Authorized Service Information: Detailed, Descriptive, and Complete If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document containing a procedure and, if required, provide, make available, or require the specific use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has recognized the need for fuel injector cleaning methods on some engines, though under normal circumstances, this service is not part of the maintenance requirements. GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning of the fuel injectors with preventative maintenance suggestions to maintain optimum performance. You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional information on this subject. Subsystem Flushing Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized practices to be performed after catastrophic failures or extreme corrosion when encountered in radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006. This practice is NOT required or recommended for normal service operations. The use of external transmission fluid exchange or flush machines is NOT recommended for the automatic or manual transmission. Use of external machines to replace the fluid may affect the operation or durability of the transmission. Transmission fluid should only be replaced by draining and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter Replacement. Approved Transmission Flushing Tool (Transmission Cooler Only) The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096. Service Is Important to You and Your Customer General Motors takes great pride in offering our dealerships and customers high quality vehicles that require extremely low maintenance over the life of the vehicle. This low cost of ownership builds repeat sales and offers our customers measurable economy of operation against competing vehicles. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 5509 Providing responsible services at the proper intervals will greatly aid your dealership with repeat business, and additional services when required. Most customers appreciate and gain trust in the dealership that informs and offers them just what they need for continued trouble-free operation. Examine your service department's practices and verify that all Service Consultants and Technicians focus on customer satisfaction, vehicle inspections, and other products at time of service. Use this opportunity to upgrade the services you provide to your customers. Here are a few suggestions: - Take the time required to align your dealership service practices with the new GM Simplified Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to create a "mirror image" in your advertising and dealer service pricing that is easily understandable to your customer. Taking advantage of this new service strategy may greatly increase your dealership service sales and customer retention while decreasing the frequency of visits and inconvenience to your customer. - Review your program to ensure that all vehicles coming in are evaluated for safety and wear items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and what the required repair would cost. In addition to the possibility of increased emissions and driveability concerns, many customers are unaware that lower gas mileage may also result, with additional cost to the customer. - Be complete in your service recommendations. Some sales opportunities are not being fully pursued nationally. Focus on overlooked but required maintenance that has real benefits to the customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow decreasing A/C and heating performance. Make sure these filters are part of your recommended service. Note that some of our vehicles may not have been factory equipped but will accept the filters as an accessory. - Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved resale value of a completely maintained vehicle. - For customers who clean and maintain the appearance of their vehicles themselves encourage the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of many customers who try it just once. If your dealership give samples of these products with new car purchases, customers may already be sold on the product but not willing to make a special trip to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with these products and consider instituting compensation programs for Service Consultants who suggest these products. Many consumers faced with an intimidating wall full of car care products sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM that they know will not harm the finish of their vehicle. We suggest these competitively priced basic vehicle care products to emphasize: In USA: - #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L) - #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g) - #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L) - #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L) - #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L) In Canada: - #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL - #992727 GM Glass Cleaner Aerosol 500 g - #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL - #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL - #10953202 GM Vehicle Care Wheel Brite 473 mL - #88901678 GM Vehicle Care Odor Eliminator 473 mL - Display signboards with the installed price for popular GM Accessories such as running boards and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a service visit. - Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer with more reasons to identify your dealership as the best place to go for parts and service. Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and provide value to your customer. Many businesses exist profitably as an oil change location, a vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and provide these services with the inherent trust of your customer, under the GM Mark of Excellence. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Electric Motor Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Remove the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 5515 4. Remove the electric motor actuator. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation. 1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 5516 2. Install the electrical connector. 3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Differential Side Bearings Replacement (8.0 Inch Axle) Carrier Bearings: Service and Repair Differential Side Bearings Replacement (8.0 Inch Axle) Differential Side Bearings Replacement (8.0 Inch Axle) Tools Required * J 8092 Universal Driver Handle- 3/4 in - 10 * J 21784 Side Bearing Installer * J 22888-D Side Bearing Puller Kit * J 45231 Differential Side Bearing Installer Removal Procedure 1. Remove the differential. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 2. Remove the differential side bearings by performing the following steps: 1. Install the differential assembly in a vise. 2. Install the J 22888-20A (2) and the J 8107-2 (1), as shown. 3. Remove the differential side bearings using the J 22888-20A . 3. Remove the differential assembly from the vise. Installation Procedure 1. Install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. 2. Install the J 45231 (2), and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 45231 (2) and the J 8092 (1). 2. Install the differential. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Differential Side Bearings Replacement (8.0 Inch Axle) > Page 5522 Carrier Bearings: Service and Repair Differential Side Bearings Replacement (8.6 Inch Axle) Differential Side Bearings Replacement (8.6 Inch Axle) Tools Required * J 22912-B Split Plate Bearing Puller * J 8092 Universal Driver Handle - 3/4 in - 10 * J 21784 Side Bearing Installer * J 22888-D Side Bearing Remover Kit * J 29710 Differential Side Bearing Installer * J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Remove the differential assembly. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 2. Remove the differential side bearings by doing the following: 1. Install the differential assembly into a vise. 2. Install the J 22888-20A (2) and the J 8107-4 , over the differential case side bearing bore. 3. Remove the differential side bearings using the J 22888-20A . Installation Procedure 1. Install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-4 in the case on the side opposite the bearing installation. 2. Install the J 21784 (2), and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 21784 or the J 29710 and the J 8092 . 2. Install the differential assembly. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair Rear Axle Housing Cover and Gasket Replacement Removal Procedure Caution: Refer to Differential Housing Cover and Gasket Removal Caution (See: Service Precautions). Note: The gasket and rear cover are reusable. Replace them only if they are damaged. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the bolt for the rear brake pipe retainer. 3. Remove the bolt for the mounting bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Page 5526 4. Remove the mounting brackets from the rear axle cover. 5. Position a suitable drain pan under the axle. 6. Remove the rear cover mounting bolts. 7. Remove the rear cover and gasket from the differential housing. 8. Drain the rear axle. Installation Procedure 1. Clean the contact area for the rear cover and gasket and the differential housing. 2. Install the retainer and mounting bracket for the rear brake pipe. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Page 5527 3. Install the mounting bolt for the mounting bracket. 4. Finger tighten the bolt for the mounting bracket. 5. Install the axle housing cover and gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the mounting bolts and tighten to 30 Nm (22 lb ft). 7. Install the retaining bolt for the brake pipe retainer and tighten to 20 Nm (14 lb ft). 8. Fill the rear axle with fluid. Refer to Rear Axle Lubricant Level Inspection (8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.0 Inch Axle))Rear Axle Lubricant Level Inspection (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6 Inch Axle)). 9. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Electric Motor Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Remove the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Page 5532 4. Remove the electric motor actuator. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation. 1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Page 5533 2. Install the electrical connector. 3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component Information > Service and Repair Differential Mount: Service and Repair Differential Carrier Assembly Bushing and Bracket Replacement Removal Procedure Note: The bushing for the mounting bracket are not serviced separately. They are serviced with the mounting bracket. 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 2. Support the front drive axle assembly. 3. Remove the mounting bracket to frame bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component Information > Service and Repair > Page 5537 4. Remove the bolts mounting the bracket to the disconnect housing. 5. Remove the mounting bracket. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component Information > Service and Repair > Page 5538 1. Position the mounting bracket to the frame. Note: In the following service procedure, DO NOT completely tighten the bolts mounting the bracket to the frame. Leave the bolts loose to allow for bracket alignment to the intermediate shaft housing. 2. Install the mounting bracket bolts to the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component Information > Service and Repair > Page 5539 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the mounting bracket bolts to the intermediate shaft housing and tighten the bolts to 152 Nm (112 lb ft). 4. Tighten the mounting bracket bolts to 152 Nm (112 lb ft). 5. Remove the support from the front drive axle assembly. 6. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DIFFERENTIAL FLUID Front Axle ...................................................................................................... ......................................................................................... 1.5 liters (3.2 pints) Rear Axle 8.0 inch ...... .............................................................................................................................................................. ............................... 1.7 liters (3.6 pints) 8.6 inch ................................................................................ ................................................................................................................. 2.03 liters (4.3 pints) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5544 Fluid - Differential: Fluid Type Specifications FRONT AND REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Ensure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Remove the engine protection shield (EPS), if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 5. Clean the area around the front axle fill plug. 6. Remove the front axle fill plug and the washer. 7. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". Note: Ensure that the pipe cleaner is resting on the bottom threads of the fill hole. 8. Insert the pipe cleaner into the fill plug opening with the stem "L" is facing down. 9. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The oil level should be between 0-8 mm (0-0.4 in) below the fill plug opening. 10. If the level is low, add fluid until the level is within the proper fluid level specification. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Install the fill plug and the washer and tighten the plug to 32 Nm (24 lb ft). 12. Install the EPS, if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 13. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.0 Inch Axle) Rear Axle Lubricant Level Inspection (8.0 Inch Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 5547 7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6 Inch Axle) Rear Axle Lubricant Level Inspection (8.6 Inch Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the fluid level is low, add lubricant until the level is within specifications. Use the proper fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 5548 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Ensure that the vehicle is level. 3. Remove the engine protection shield (EPS), if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Remove the drain plug. 5. Drain axle fluid into a suitable container. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the drain plug and tighten to 32 Nm (24 lb ft). 7. Remove the fill plug. 8. Fill the drive axle with the proper fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 9. Inspect the fluid level. Refer to Front Axle Lubricant Level Inspection (See: Procedures/Front Drive Axle). 10. Install the fill plug and tighten to 32 Nm (24 lb ft). 11. Install the EPS, if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 12. Lower the vehicle. Rear Axle Lubricant Replacement (8.0 Inch Axle) Rear Axle Lubricant Replacement (8.0 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Differential Cover/Service and Repair). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Differential Cover/Service and Repair). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (8.6 Inch Axle) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 5549 Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Differential Cover/Service and Repair). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Differential Cover/Service and Repair). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Service Intervals) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) /. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 5550 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle Pinion Bearing: Service and Repair Rear Drive Axle Drive Pinion Bearings Replacement (8.6 Inch Axle) Special Tools * DT 49032 - Pinion Bearing Cup Installer * DT 49275 - Pinion Bearing Remover * J 8092 - Universal Driver Handle 3/4 in-10 * J 22828 - Input Shaft Gear Installer * J 22912-B - Bearing Remover * J 28677 - Needle Bearing Installer Disassemble Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential assembly. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 3. Remove the differential drive pinion gear from the axle. Refer to Drive Pinion and Ring Gear Replacement (See: Pinion Gear/Service and Repair/Rear Drive Axle). 4. Using the DT 49275 - remover and the J 22912-B - puller , remove the differential drive pinion gear bearing and the spacer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5555 Note: Position the brass drift in the slots provided in the axle housing. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 5. Using a hammer and a brass drift, remove the outer differential drive pinion gear bearing cup. Note: Position the brass drift in the slots provided in the axle housing. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 6. Using a hammer and a brass drift, remove the inner differential drive pinion gear bearing cup. Assemble Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5556 1. Using the J 28677 - installer (1) and the J 8092 - handle (2), install the outer differential drive pinion gear bearing cup. 2. Using the DT 49032 - installer (1) and the J 8092 - handle (2), install the inner differential drive pinion gear cup. 3. Determine the selective spacer thickness for the pinion. Refer to Pinion Depth Adjustment (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.0 Inch Axle))Pinion Depth Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.6 Inch Axle)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5557 4. Install the selective pinion spacer (1) on the pinion gear (2). 5. Using the J 22828 - installer and a hammer, install the differential drive pinion gear bearing and the spacer. Note: Use the proper fluid. 6. Lubricate the pinion bearings with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). 7. Install the differential drive pinion gear outer bearing into the axle housing. 8. Install the differential drive pinion gear into the axle housing. 9. Install the NEW differential drive pinion gear seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 10. Install the differential assembly. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 11. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)). 12. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5558 Pinion Bearing: Service and Repair Front Drive Axle Drive Pinion Bearings Replacement Special Tools * J 5590 Pinion Bearing Race Installer - Rear * J 7817 Outer Bearing Race Installer * J 8092 Universal Driver Handle- 3/4 in - 10 * J 8614-01 Flange and Pulley Holding Tool * J 21128 Axle Pinion Oil Seal Installer * J 22912-B Split-Plate Bearing Puller * J 29609 Rear Pinion Bearing Cup Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (See: Differential Carrier/Service and Repair). 3. Remove the drive pinion from the axle. Refer to Drive Pinion and Ring Gear Replacement (See: Pinion Gear/Service and Repair/Front Drive Axle). 4. Press the bearing off of the pinion using the J 22912-B . 5. Remove the shim. 6. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5559 7. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Installation Procedure 1. Install the outer pinion bearing cup using the J 7817 (1) and the J 8092 (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5560 2. Install the inner pinion bearing cup using the J 29609 (2) and the J 8092 (1). 3. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment (See: Service and Repair/Removal and Replacement/Front Drive Axle/Pinion Depth Adjustment). 4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5. Install the inner pinion bearing using the J 5590 . Press the bearing on until the cone seats on the pinion shim. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 8. Install the pinion into the axle housing. 9. Install the outer pinion bearing onto the pinion. 10. Install a new pinion oil seal using the J 21128 . 11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5561 12. Install the pinion yoke. Align the marks made during removal. 13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut. 15. Install the J 8614-01 onto the pinion yoke as shown. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 16. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 17. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 18. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5562 20. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (See: Differential Carrier/Service and Repair). 21. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 21128 Axle Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 4. Remove the brake calipers. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 5. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion seal * The carrier bearings * The axle bearings * The axle seals 6. Scribe an alignment line between the pinion shaft and the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5567 7. Install the J 8614-01 (1) onto the pinion as shown. 8. Remove the pinion nut while holding the J 8614-01 (1). 9. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 10. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Note: Carefully remove the seal from the bore. Do not distort or scratch the aluminum case. 11. Remove the oil seal using a suitable seal removal tool. 12. Remove the dust deflector from the pinion yoke using a soft-faced hammer. Installation Procedure 1. Install the new deflector onto the pinion yoke using a soft-faced hammer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5568 Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing. 2. Install the new oil seal by doing the following: 1. Position the oil seal in the bore. 2. Install the J 21128 over the oil seal. 3. Strike the J 21128 with a hammer until the seal flange seats on the axle housing surface. 3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 4. Install the pinion yoke. Align the reference marks made during removal. Caution: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 5. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 6. Install the washer and a new pinion nut. 7. Install the J 8614-01 (1) onto the pinion yoke as shown. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Tighten the pinion nut while holding the J 8614-01 (1). Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 9. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement of the rotating torque to the measurement recorded earlier. The rotating torque of the pinion nut should be 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 10. If the rotating torque is not within specifications, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 11. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 12. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 13. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 14. Install the brake calipers. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 15. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle). 16. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5569 Pinion Flange: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 33782 - Pinion Oil Seal Installer * J 38694 - Extension Housing Oil Pump/Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly 1. Raise the and support vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear drum brakes. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 3. Remove the propeller shaft. * For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 4. Use an inch-pound torque wrench, measure the amount of torque required to rotate the pinion. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion oil seal * The differential case bearings * The axle bearings * The axle seals 5. Place an alignment mark between the pinion and the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5570 6. Using the J 8614-01 - tool to hold the pinion nut, remove the pinion nut and the washer. Note: Use a container in order to retrieve the lubricant. 7. Using the J 8614-01 - tool (1) to hold the pinion yoke, remove the pinion yoke by turning the J 8614-3 (3) clockwise. Note: Do not damage the housing. 8. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 33782 - installer for the 8.0 inch, install the pinion seal. 2. Apply sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5571 3. Align the reference marks and install the pinion yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 4. Using a soft-faced hammer, tap the pinion yoke until the threads on the pinion shaft can be seen. 5. Install the washer and a NEW pinion nut. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. While holding the J 8614-01 - tool , tighten the NEW pinion nut in small increments until the end play is just taken up. Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. Note: Compare this measurement with the rotating torque recorded during removal. 7. Using an inch pound torque wrench, measure the rotating torque of the pinion0.40-0.57 Nm (3-5 lb in) greater than the rotating torque recorded during removal.. 8. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 9. Install the propeller shaft. * For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5572 10. Install the rear brake rotors. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 11. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)). 12. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle Pinion Gear: Service and Repair Rear Drive Axle Drive Pinion and Ring Gear Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 22536 Pinion Driver * J 38694 Extension Housing Oil Pump/Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 3. Remove the differential assembly. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 4. Remove the drive pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the collapsible spacer from the pinion. Discard the spacer. 8. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)). 9. Remove the left-hand threaded ring gear bolts. Discard the bolts. 10. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5577 Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 1. Install the ring gear to the differential case. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft). 4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)). 5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.0 Inch Axle))Pinion Depth Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.6 Inch Axle)). 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)). 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 10. Install the pinion to the axle housing. 11. Install the outer pinion bearing. 12. Install a new pinion oil seal using the J 38694 . 13. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5578 14. Install the pinion yoke. Align the marks made during removal. 15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut. 17. Install the J 8614-01 onto the pinion yoke as shown. Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 18. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle ). 19. Install the differential. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 20. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Gear Tooth Contact Pattern Inspection). 21. Install the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 22. Fill the axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)). 23. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5579 Pinion Gear: Service and Repair Front Drive Axle Drive Pinion and Ring Gear Replacement Special Tools * J 8001 Dial Indicator Set * J 8614-01 Flange and Pulley Holding Tool * J 21128 Axle Pinion Oil Seal Installer * J 22536 Pinion Driver * J 22779 Side Bearing Backlash Gage * J 25025 Guide Pins * J 25588 Side Bearing Shim Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (See: Differential Carrier/Service and Repair). 3. Remove the drive pinion yoke and the oil seal. Refer to Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement (See: Pinion Flange/Service and Repair/Front Drive Axle). 4. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front Drive Axle). 8. Remove the ring gear. Refer to Front Differential Case Disassemble (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Differential Case Disassemble). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5580 Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 1. Install the ring gear to the differential case. Refer to Front Differential Case Disassemble (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Differential Case Disassemble). 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft). 4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front Drive Axle). 5. Determine the selective shim thickness for the pinion gear. See Differential Side Bearing Preload Adjustment Procedure below. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front Drive Axle). 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 10. Install the pinion to the axle housing. 11. Install the outer pinion bearing. 12. Install a new pinion oil seal using the J 21128 . 13. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5581 14. Install the pinion yoke. Align the marks made during removal. 15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut. 17. Install the J 8614-01 onto the pinion yoke as shown. Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 18. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 19. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4 Nm (15-30 lb in) for new bearings. 20. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4 Nm (15-30 lb in) for new bearings. 21. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 22. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (See: Differential Carrier/Service and Repair). 23. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection (See: Service and Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection). 24. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5582 Differential Side Bearing Preload Adjustment Procedure Important: * The differential side bearing preload adjustment must be completed before the backlash adjustment can be started. * In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right side shim packs equally. * Measure the service shims and the spacers one at a time. Add the measurements together in order to obtain the total thickness of the left or the right side shim pack. * Do not use or reuse the original cast iron production shims. Use service shims and spacers instead. 1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement (See: Rear Drive Axle). 2. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. The rotating torque of the drive pinion should be 1.7-3.4 Nm (15-30 lb in) for new bearings or 1.1-2.3 Nm(10-20 lb in) for used bearings. 3. Record the measurement. Important: Before installation of the differential assembly, ensure that the side bearing surfaces in the axle housing are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used. 4. Install the differential assembly with the side bearings and bearing cups into the axle housing. 5. Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing. 6. Side the differential assembly towards the service spacer in order to hold the spacer in place. 7. Install the J 22779 between the right side differential side bearing cup and the axle housing. Important: Over-tightening may spread the housing and result in incorrect shim selection. 8. Tighten the knob on the J 22779 until there is moderate drag when the J 22779 is moved. 9. Remove the J 22779 . 10. Remove the service spacer. 11. Using a micrometer, measure the thickness of the J 22779 in 3 locations. 12. Calculate the average of the 3 measurements. Record the measurement. 13. Using a micrometer, measure the thickness of the service spacer. Record the measurement. 14. Add the thickness of the service spacer to the average thickness of the J 22779 . The resulting value is the total service shim thickness without preload for the axle. 15. Insert one 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the axle housing. 16. Insert one BENT 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the service shim. 17. Install the J 22779 on the left side of the differential assembly. 18. While rotating the ring gear back and forth, tighten the knob on the J 22779 until there is approximately 0.025-0.051 mm (0.001-0.002 in) of backlash between the ring gear and the drive pinion. 19. Once the amount of backlash is obtained, remove the J 22779 . 20. Remove the differential case with the differential side bearings and the bearing cups. 21. Remove the service shims. 22. Using a micrometer, measure the thickness of the J 22779 in 3 locations. 23. Calculate the average of the 3 measurements. This value is the left side service shim thickness without preload. 24. Subtract the service shim thickness for the left side of the axle, calculated in step 23, from the total service shim thickness, calculated in step 14. This value is the service shim thickness for the right side of the axle without preload. 25. In order to initially set the preload of the differential side bearings and the backlash to approximately 0.013-0.023 mm (0.005-0.009 in), take the value determined in step 24 and add 0.0203 mm (0.008 in) service shim thickness to this amount. 26. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 23. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness. 27. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 25. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness. 28. Install the differential assembly with the differential side bearings and the differential side bearing cups. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5583 29. Install the left side service spacer between the axle housing and the differential assembly. 30. Install the left side selective service shim or shims. The service shim or shims must be installed between the service spacer and the differential side bearing cup. 31. Install the right side service spacer between the axle housing and the differential assembly. 32. Install the right side selective service shim or shims using the J 25588 , if necessary. The service shim or shims must be installed between the service spacer and the differential side bearing cup. 33. Install the differential bearing caps and the bolts. Tighten the differential bearing cap bolts to 63 Nm (46 lb ft). 34. Measure the drive pinion and differential side bearing preload using an inch-pound torque wrench. Rotate the pinion several times to ensure the differential side bearings have seated. The rotating torque of the drive pinion and differential side bearings should be 3.9-6.2 Nm (30-55 lb in) for new bearings or 2.8-5.1 Nm (25-45 lb in) for used bearings. Record the measurement. 35. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and differential case bearing preload, measured in Step 33. Multiply the value obtained by the axle ratio. The differential case side bearing preload should be 1.7-4.0 Nm (15-35 lb in). 36. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload. 37. Once the differential side bearing preload is correct, measure the backlash and adjust, if necessary. Refer to Backlash Inspection and Adjustment (See: Service and Repair/Removal and Replacement/Front Drive Axle/Backlash Inspection and Adjustment). 38. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection (See: Service and Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle Ring Gear: Service and Repair Rear Drive Axle Drive Pinion and Ring Gear Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 22536 Pinion Driver * J 38694 Extension Housing Oil Pump/Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 3. Remove the differential assembly. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 4. Remove the drive pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the collapsible spacer from the pinion. Discard the spacer. 8. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)). 9. Remove the left-hand threaded ring gear bolts. Discard the bolts. 10. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5588 Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 1. Install the ring gear to the differential case. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft). 4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)). 5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.0 Inch Axle))Pinion Depth Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.6 Inch Axle)). 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) (See: Pinion Bearing/Service and Repair/Rear Drive Axle)Drive Pinion Bearings Replacement (8.0 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Drive Pinion Bearings Replacement (8.0 Inch Axle)). 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 10. Install the pinion to the axle housing. 11. Install the outer pinion bearing. 12. Install a new pinion oil seal using the J 38694 . 13. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5589 14. Install the pinion yoke. Align the marks made during removal. 15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut. 17. Install the J 8614-01 onto the pinion yoke as shown. Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 18. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle ). 19. Install the differential. Refer to Differential Replacement (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Replacement). 20. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Gear Tooth Contact Pattern Inspection). 21. Install the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 22. Fill the axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)). 23. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5590 Ring Gear: Service and Repair Front Drive Axle Drive Pinion and Ring Gear Replacement Special Tools * J 8001 Dial Indicator Set * J 8614-01 Flange and Pulley Holding Tool * J 21128 Axle Pinion Oil Seal Installer * J 22536 Pinion Driver * J 22779 Side Bearing Backlash Gage * J 25025 Guide Pins * J 25588 Side Bearing Shim Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (See: Differential Carrier/Service and Repair). 3. Remove the drive pinion yoke and the oil seal. Refer to Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement (See: Pinion Flange/Service and Repair/Front Drive Axle). 4. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front Drive Axle). 8. Remove the ring gear. Refer to Front Differential Case Disassemble (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Differential Case Disassemble). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5591 Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 1. Install the ring gear to the differential case. Refer to Front Differential Case Disassemble (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Differential Case Disassemble). 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 120 Nm (89 lb ft). 4. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front Drive Axle). 5. Determine the selective shim thickness for the pinion gear. See Differential Side Bearing Preload Adjustment Procedure below. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair/Front Drive Axle). 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 10. Install the pinion to the axle housing. 11. Install the outer pinion bearing. 12. Install a new pinion oil seal using the J 21128 . 13. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5592 14. Install the pinion yoke. Align the marks made during removal. 15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut. 17. Install the J 8614-01 onto the pinion yoke as shown. Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 18. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 19. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4 Nm (15-30 lb in) for new bearings. 20. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0-2.3 Nm (10-20 lb in) for used bearings or 1.7-3.4 Nm (15-30 lb in) for new bearings. 21. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 22. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (See: Differential Carrier/Service and Repair). 23. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection (See: Service and Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection). 24. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5593 Differential Side Bearing Preload Adjustment Procedure Important: * The differential side bearing preload adjustment must be completed before the backlash adjustment can be started. * In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right side shim packs equally. * Measure the service shims and the spacers one at a time. Add the measurements together in order to obtain the total thickness of the left or the right side shim pack. * Do not use or reuse the original cast iron production shims. Use service shims and spacers instead. 1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement (See: Pinion Gear/Service and Repair/Rear Drive Axle). 2. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. The rotating torque of the drive pinion should be 1.7-3.4 Nm (15-30 lb in) for new bearings or 1.1-2.3 Nm(10-20 lb in) for used bearings. 3. Record the measurement. Important: Before installation of the differential assembly, ensure that the side bearing surfaces in the axle housing are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used. 4. Install the differential assembly with the side bearings and bearing cups into the axle housing. 5. Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing. 6. Side the differential assembly towards the service spacer in order to hold the spacer in place. 7. Install the J 22779 between the right side differential side bearing cup and the axle housing. Important: Over-tightening may spread the housing and result in incorrect shim selection. 8. Tighten the knob on the J 22779 until there is moderate drag when the J 22779 is moved. 9. Remove the J 22779 . 10. Remove the service spacer. 11. Using a micrometer, measure the thickness of the J 22779 in 3 locations. 12. Calculate the average of the 3 measurements. Record the measurement. 13. Using a micrometer, measure the thickness of the service spacer. Record the measurement. 14. Add the thickness of the service spacer to the average thickness of the J 22779 . The resulting value is the total service shim thickness without preload for the axle. 15. Insert one 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the axle housing. 16. Insert one BENT 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the service shim. 17. Install the J 22779 on the left side of the differential assembly. 18. While rotating the ring gear back and forth, tighten the knob on the J 22779 until there is approximately 0.025-0.051 mm (0.001-0.002 in) of backlash between the ring gear and the drive pinion. 19. Once the amount of backlash is obtained, remove the J 22779 . 20. Remove the differential case with the differential side bearings and the bearing cups. 21. Remove the service shims. 22. Using a micrometer, measure the thickness of the J 22779 in 3 locations. 23. Calculate the average of the 3 measurements. This value is the left side service shim thickness without preload. 24. Subtract the service shim thickness for the left side of the axle, calculated in step 23, from the total service shim thickness, calculated in step 14. This value is the service shim thickness for the right side of the axle without preload. 25. In order to initially set the preload of the differential side bearings and the backlash to approximately 0.013-0.023 mm (0.005-0.009 in), take the value determined in step 24 and add 0.0203 mm (0.008 in) service shim thickness to this amount. 26. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 23. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness. 27. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 25. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness. 28. Install the differential assembly with the differential side bearings and the differential side bearing cups. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Drive Axle > Page 5594 29. Install the left side service spacer between the axle housing and the differential assembly. 30. Install the left side selective service shim or shims. The service shim or shims must be installed between the service spacer and the differential side bearing cup. 31. Install the right side service spacer between the axle housing and the differential assembly. 32. Install the right side selective service shim or shims using the J 25588 , if necessary. The service shim or shims must be installed between the service spacer and the differential side bearing cup. 33. Install the differential bearing caps and the bolts. Tighten the differential bearing cap bolts to 63 Nm (46 lb ft). 34. Measure the drive pinion and differential side bearing preload using an inch-pound torque wrench. Rotate the pinion several times to ensure the differential side bearings have seated. The rotating torque of the drive pinion and differential side bearings should be 3.9-6.2 Nm (30-55 lb in) for new bearings or 2.8-5.1 Nm (25-45 lb in) for used bearings. Record the measurement. 35. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and differential case bearing preload, measured in Step 33. Multiply the value obtained by the axle ratio. The differential case side bearing preload should be 1.7-4.0 Nm (15-35 lb in). 36. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload. 37. Once the differential side bearing preload is correct, measure the backlash and adjust, if necessary. Refer to Backlash Inspection and Adjustment (See: Service and Repair/Removal and Replacement/Front Drive Axle/Backlash Inspection and Adjustment). 38. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection (See: Service and Repair/Removal and Replacement/Front Drive Axle/Gear Tooth Contact Pattern Inspection). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 21128 Axle Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 4. Remove the brake calipers. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 5. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion seal * The carrier bearings * The axle bearings * The axle seals 6. Scribe an alignment line between the pinion shaft and the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5599 7. Install the J 8614-01 (1) onto the pinion as shown. 8. Remove the pinion nut while holding the J 8614-01 (1). 9. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 10. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Note: Carefully remove the seal from the bore. Do not distort or scratch the aluminum case. 11. Remove the oil seal using a suitable seal removal tool. 12. Remove the dust deflector from the pinion yoke using a soft-faced hammer. Installation Procedure 1. Install the new deflector onto the pinion yoke using a soft-faced hammer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5600 Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing. 2. Install the new oil seal by doing the following: 1. Position the oil seal in the bore. 2. Install the J 21128 over the oil seal. 3. Strike the J 21128 with a hammer until the seal flange seats on the axle housing surface. 3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 4. Install the pinion yoke. Align the reference marks made during removal. Caution: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 5. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 6. Install the washer and a new pinion nut. 7. Install the J 8614-01 (1) onto the pinion yoke as shown. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Tighten the pinion nut while holding the J 8614-01 (1). Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 9. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement of the rotating torque to the measurement recorded earlier. The rotating torque of the pinion nut should be 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 10. If the rotating torque is not within specifications, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 11. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 12. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 13. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 14. Install the brake calipers. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 15. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle). 16. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5601 Seals and Gaskets: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 33782 - Pinion Oil Seal Installer * J 38694 - Extension Housing Oil Pump/Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly 1. Raise the and support vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear drum brakes. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 3. Remove the propeller shaft. * For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 4. Use an inch-pound torque wrench, measure the amount of torque required to rotate the pinion. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion oil seal * The differential case bearings * The axle bearings * The axle seals 5. Place an alignment mark between the pinion and the pinion yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5602 6. Using the J 8614-01 - tool to hold the pinion nut, remove the pinion nut and the washer. Note: Use a container in order to retrieve the lubricant. 7. Using the J 8614-01 - tool (1) to hold the pinion yoke, remove the pinion yoke by turning the J 8614-3 (3) clockwise. Note: Do not damage the housing. 8. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 33782 - installer for the 8.0 inch, install the pinion seal. 2. Apply sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5603 3. Align the reference marks and install the pinion yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 4. Using a soft-faced hammer, tap the pinion yoke until the threads on the pinion shaft can be seen. 5. Install the washer and a NEW pinion nut. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. While holding the J 8614-01 - tool , tighten the NEW pinion nut in small increments until the end play is just taken up. Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. Note: Compare this measurement with the rotating torque recorded during removal. 7. Using an inch pound torque wrench, measure the rotating torque of the pinion0.40-0.57 Nm (3-5 lb in) greater than the rotating torque recorded during removal.. 8. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 9. Install the propeller shaft. * For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5604 10. Install the rear brake rotors. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 11. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)). 12. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Drive Axle Axle Bearing: Service and Repair Front Drive Axle Front Drive Axle Seal and Bearing Replacement Tools Required * J 2619-01 Slide Hammer * J 8092 Universal Drive Handle 3/4 Inch - 10 * J 21426 Extension Housing Seal Installer * J 29369-2 Bushing and Bearing Remover 2-3 inch * J 45232 Differential Bearing Adjuster Needle Bearing Installer - Left Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Drive Axle > Page 5610 2. Remove the swaybar link from the lower control arm. Refer to Stabilizer Shaft Link Replacement (ZQ8, Z85) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement (Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)). 3. Using the J 29369-2 (2) and the J 2619-01 (1) , remove the axle seal. 4. Using the J 29369-2 (1) and the J 2619-01 (2) , remove the axle bearing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Drive Axle > Page 5611 1. Position the axle bearing in the intermediate housing. 2. Using the J 45232 (1) and the J 8092 (2) , install the axle bearing. 3. Using the J 21426 (1) , install the axle seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Drive Axle > Page 5612 4. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair). 5. Install the swaybar link to the lower control arm. Refer to Stabilizer Shaft Link Replacement (ZQ8, Z85) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement (Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)). 6. Check in fluid level. Refer to Front Axle Lubricant Level Inspection (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Front Drive Axle). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Drive Axle > Page 5613 Axle Bearing: Service and Repair Rear Drive Axle Rear Axle Shaft Seal and/or Bearing Replacement Tools Required * J 8092 Universal Driver Handle- 3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer * J 23690 Bearing Installer * J 2619-01 Slide Hammer * J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair). 4. Using the J 44685 and the J 2619-01 , remove the axle shaft bearing and seal. Installation Procedure 1. Using the J 23690 and the J 8092 , install the axle bearing. 2. Using the J 21128 , install the axle shaft seal. 3. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair). 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 5. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch Axle) )Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair Rear Axle Shaft Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning ). 1. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 2. Remove the clip retaining the rear brake drum, if required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5618 3. Remove the rear brake drums from the vehicle. 4. Remove the rear axle housing cover. 5. Remove the lock pin bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5619 6. Remove the pinion shaft. 7. Remove the C-lock from the rear axle. 8. Remove the rear axle shaft. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5620 1. Install the rear axle shaft. 2. Install the C-lock to the rear axle. 3. Install the pinion shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5621 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the lock bolt and tighten to 25 Nm (18 lb ft). 5. Install the rear brake drums from the vehicle. 6. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (See: Differential Assembly/Differential Cover/Service and Repair). 7. Fill the rear axle with fluid. Refer to Rear Axle Lubricant Replacement (8.0 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.0 Inch Axle))Rear Axle Lubricant Replacement (8.6 Inch Axle) (See: Differential Assembly/Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Rear Axle Lubricant Replacement (8.6 Inch Axle)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5622 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J 35910 Drive Axle Seal Clamp Plier * J 8059 Snap Ring Pliers Removal Procedure Note: Before placing the driveshaft in a vise, place protective covers over the vise jaws. 1. Place the driveshaft in a vise. Note: Do not damage the D/O joint housing while using the hand grinder. 2. Use a hand grinder to cut through the large retaining clamp (2) located at the D/O joint (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5627 Discard the large retaining clamp. 3. Use a hand grinder to cut through the small retaining clamp (4) on the small end of the seal (3). Discard the small retaining clamp. 4. Slide the seal (2) down the driveshaft bar and away from the D/O joint (1). 5. Remove the D/O joint housing in the following manner: 6. Collapse and remove the D/O ball retaining ring using a common hand tool (screwdriver). 7. Pull the D/O joint housing from the driveshaft bar. 8. Using J 8059 , spread the small retaining ring (1) located in the cage and inner race assembly (3). 9. Remove the cage and the inner race assembly (1) from the driveshaft bar (2). 10. Remove the balls. 11. Remove the inner race from the cage. 12. Thoroughly degrease all parts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5628 13. Remove the seal and discard. 14. Clean the driveshaft bar, Use a wire brush to remove any rust in the seal mounting areas (grooves). Check the D/O joint housing for unusual wear, cracks, or other damage. Replace the assembly if any damaged parts are evident. Installation Procedure 1. Install the new small retaining clamp (2) onto the neck of the seal (1). 2. Slide the small retaining clamp and seal to their proper position on the driveshaft bar (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Secure the small retaining clamp using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small retaining clamp (2) to 136 Nm (100 lb ft). Note: The cage (3) is NOT symmetrical; the larger outside diameter is the bottom of the cage. 4. Place the cage on the table large diameter side up. 5. Place the inner race (2) with retaining ring side up into the cage. 6. Place the six balls (1) in the cage windows. 7. Slide the cage/inner race assembly, small cage diameter first, onto the driveshaft bar. 8. Install the small retaining ring (1) using J 8059 into the groove of the driveshaft bar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5629 9. Pack the seal and D/O joint housing with the grease suppled in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 10. Place the new large retaining clamp on the seal. 11. Slide the D/O joint housing over the cage and inner race assembly. 12. Insert the D/O ball retaining ring into the groove at the top of the D/O joint housing. 13. Install the seal onto the D/O joint housing. 14. Check the inboard stroke position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5630 15. Secure the new large retaining clamp and the seal to the D/O joint housing using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the large retaining clamp to 176 Nm (130 lb ft). 16. Fully stroke the D/O joint several times to disperse the grease. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5631 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 35910 Drive Axle Seal Clamp Plier * J 8059 Snap Ring Pliers Removal Procedure Note: When replacing the outer seal you MUST replace the inner seal. 1. Remove the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement (See: Wheel Drive Shaft Inner Joint and Boot Replacement ). Note: Do not damage the outer race while using the hand grinder. 2. Use a hand grinder to cut through the large retaining clamp (3) located at the C/V joint (4). Discard the large retaining clamp. 3. Use a hand grinder to cut through the small retaining clamp (1) on the small end of the outer seal (2). Discard the small retaining clamp. Note: Do NOT remove the C/V joint from the driveshaft bar. If the C/V joint is removed from the driveshaft bar you must replace the whole driveshaft assembly. 4. Remove the outer seal (1) from the C/V joint (2). Slide the outer seal (1) away from the C/V joint (2) and remove from the driveshaft bar. Discard the outer seal. 5. Clean the old grease out of the C/V joint and allow to thoroughly dry. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5632 1. Pack the C/V joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 2. Place the new small retaining clamp onto the outer seal. 3. Place the new large retaining clamp on the outer seal. 4. Position the small end of the outer seal into the C/V joint outer seal groove on the driveshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Secure the small retaining clamp to the outer seal with J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small retaining clamp to 136 Nm (100 lb ft). 6. Slide the large diameter of the outer seal (1), with the large retaining ring (2) in place, over the outside edge of the C/V joint (3). 7. Position the lip of the outer seal (1) into the groove on the C/V joint (3). 8. Manipulate the outer seal (1) to remove any excess air. 9. Secure the large retaining clamp to the C/V joint housing with J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the large retaining clamp to 176 Nm (130 lb ft). 10. Check the gap dimension on the clamp ear. 11. Angulate the C/V joint several times to disperse the grease. 12. Install the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement (See: Wheel Drive Shaft Inner Joint and Boot Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J 35910 Drive Axle Seal Clamp Plier * J 8059 Snap Ring Pliers Removal Procedure Note: Before placing the driveshaft in a vise, place protective covers over the vise jaws. 1. Place the driveshaft in a vise. Note: Do not damage the D/O joint housing while using the hand grinder. 2. Use a hand grinder to cut through the large retaining clamp (2) located at the D/O joint (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5637 Discard the large retaining clamp. 3. Use a hand grinder to cut through the small retaining clamp (4) on the small end of the seal (3). Discard the small retaining clamp. 4. Slide the seal (2) down the driveshaft bar and away from the D/O joint (1). 5. Remove the D/O joint housing in the following manner: 6. Collapse and remove the D/O ball retaining ring using a common hand tool (screwdriver). 7. Pull the D/O joint housing from the driveshaft bar. 8. Using J 8059 , spread the small retaining ring (1) located in the cage and inner race assembly (3). 9. Remove the cage and the inner race assembly (1) from the driveshaft bar (2). 10. Remove the balls. 11. Remove the inner race from the cage. 12. Thoroughly degrease all parts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5638 13. Remove the seal and discard. 14. Clean the driveshaft bar, Use a wire brush to remove any rust in the seal mounting areas (grooves). Check the D/O joint housing for unusual wear, cracks, or other damage. Replace the assembly if any damaged parts are evident. Installation Procedure 1. Install the new small retaining clamp (2) onto the neck of the seal (1). 2. Slide the small retaining clamp and seal to their proper position on the driveshaft bar (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Secure the small retaining clamp using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small retaining clamp (2) to 136 Nm (100 lb ft). Note: The cage (3) is NOT symmetrical; the larger outside diameter is the bottom of the cage. 4. Place the cage on the table large diameter side up. 5. Place the inner race (2) with retaining ring side up into the cage. 6. Place the six balls (1) in the cage windows. 7. Slide the cage/inner race assembly, small cage diameter first, onto the driveshaft bar. 8. Install the small retaining ring (1) using J 8059 into the groove of the driveshaft bar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5639 9. Pack the seal and D/O joint housing with the grease suppled in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 10. Place the new large retaining clamp on the seal. 11. Slide the D/O joint housing over the cage and inner race assembly. 12. Insert the D/O ball retaining ring into the groove at the top of the D/O joint housing. 13. Install the seal onto the D/O joint housing. 14. Check the inboard stroke position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5640 15. Secure the new large retaining clamp and the seal to the D/O joint housing using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the large retaining clamp to 176 Nm (130 lb ft). 16. Fully stroke the D/O joint several times to disperse the grease. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5641 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 35910 Drive Axle Seal Clamp Plier * J 8059 Snap Ring Pliers Removal Procedure Note: When replacing the outer seal you MUST replace the inner seal. 1. Remove the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement (See: Constant Velocity Joint/Service and Repair/Wheel Drive Shaft Inner Joint and Boot Replacement). Note: Do not damage the outer race while using the hand grinder. 2. Use a hand grinder to cut through the large retaining clamp (3) located at the C/V joint (4). Discard the large retaining clamp. 3. Use a hand grinder to cut through the small retaining clamp (1) on the small end of the outer seal (2). Discard the small retaining clamp. Note: Do NOT remove the C/V joint from the driveshaft bar. If the C/V joint is removed from the driveshaft bar you must replace the whole driveshaft assembly. 4. Remove the outer seal (1) from the C/V joint (2). Slide the outer seal (1) away from the C/V joint (2) and remove from the driveshaft bar. Discard the outer seal. 5. Clean the old grease out of the C/V joint and allow to thoroughly dry. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 5642 1. Pack the C/V joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 2. Place the new small retaining clamp onto the outer seal. 3. Place the new large retaining clamp on the outer seal. 4. Position the small end of the outer seal into the C/V joint outer seal groove on the driveshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Secure the small retaining clamp to the outer seal with J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small retaining clamp to 136 Nm (100 lb ft). 6. Slide the large diameter of the outer seal (1), with the large retaining ring (2) in place, over the outside edge of the C/V joint (3). 7. Position the lip of the outer seal (1) into the groove on the C/V joint (3). 8. Manipulate the outer seal (1) to remove any excess air. 9. Secure the large retaining clamp to the C/V joint housing with J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the large retaining clamp to 176 Nm (130 lb ft). 10. Check the gap dimension on the clamp ear. 11. Angulate the C/V joint several times to disperse the grease. 12. Install the inner seal. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement (See: Constant Velocity Joint/Service and Repair/Wheel Drive Shaft Inner Joint and Boot Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair Seals and Gaskets: Service and Repair Front Drive Axle Seal and Bearing Replacement Tools Required * J 2619-01 Slide Hammer * J 8092 Universal Drive Handle 3/4 Inch - 10 * J 21426 Extension Housing Seal Installer * J 29369-2 Bushing and Bearing Remover 2-3 inch * J 45232 Differential Bearing Adjuster Needle Bearing Installer - Left Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair). 2. Remove the swaybar link from the lower control arm. Refer to Stabilizer Shaft Link Replacement (ZQ8, Z85) (See: Steering and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Page 5646 Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement (Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)). 3. Using the J 29369-2 (2) and the J 2619-01 (1) , remove the axle seal. 4. Using the J 29369-2 (1) and the J 2619-01 (2) , remove the axle bearing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Page 5647 1. Position the axle bearing in the intermediate housing. 2. Using the J 45232 (1) and the J 8092 (2) , install the axle bearing. 3. Using the J 21426 (1) , install the axle seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Page 5648 4. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair). 5. Install the swaybar link to the lower control arm. Refer to Stabilizer Shaft Link Replacement (ZQ8, Z85) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85) )Stabilizer Shaft Link Replacement (Z71) (See: Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)). 6. Check in fluid level. Refer to Front Axle Lubricant Level Inspection (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Front Drive Axle). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5652 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning ). Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/ABS Component Handling Warning). 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5653 4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled in any of the suspension components. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5654 6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly. 7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5655 Note: Perform the following service procedure with the brake rotor on a flat surface. 8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor. Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor is removed. 9. Remove the wheel bearing/hub from the brake rotor. 10. Clean the contact area between the wheel bearing/hub and the brake rotor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5656 1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from the wheel bearing/hub assembly to the brake rotor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The following service procedure is to be performed on a flat surface and to ensure that the brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT use air tools of any type for this procedure. 3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install the backing plate to the wheel bearing/hub, brake rotor assembly. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5657 6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle. Note: When performing the following service procedure, DO NOT use air tools of any type to torque the brake rotor to hub bolts. 7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5658 8. Install the brake caliper mounting bracket to the steering knuckle. 9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5659 10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake caliper mounting bracket. Note: The following service procedure is to ensure that the brake rotor is seated properly on the wheel bearing/hub assembly. 11. Tighten the mounting bolts for the brake rotor in sequence. 12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). 14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications (See: Brakes and Traction Control/Disc Brake System/Specifications/Disc Brake Component Specifications). 15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Shaft Nut .................................................................................................................................... .................................................... 260 Nm (191 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Special Tools * J 37372 Bearing Installer * J 44749 Split Plate Removal Procedure 1. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 2. Mark the relationship of the yoke to the driveshaft. 3. Mark the relationship of the U-Joint to the yoke. 4. Remove the U-Joint from the yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5668 Note: The following service is to protect the machined portion of the slip yoke. 5. Using 2 or 3 clean shop towels, wrap the slip yoke with the towels and secure with electrical ties or electrical tape. 6. Remove the retaining nut for the yoke. 7. Remove the washer from the yoke. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5669 8. Remove the yoke from the propeller shaft. Note: When installing the special tool, the aid of an assistant will be required to position the tool between the center bearing and propeller shaft shoulder. Ensure that the flat part of the tool is facing center bearing. 9. Install the J 44749 (1) to the propeller shaft. 1. With the aid of an assistant, pull the center bearing toward the spline part of the propeller shaft. 2. Position the tool (1) between the center bearing and the shield for the center bearing. 3. Adjust the tool so that it just comes in contact with the shoulder. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5670 Note: It will be necessary to adjust the hydraulic press so that the slip yoke does not touch the ground. 10. Install the propeller shaft in a hydraulic press. 11. Position a piece of wood between the floor and the slip yoke. 12. Remove the center bearing (1) from the propeller shaft. 13. Remove the tool from the propeller shaft. Installation Procedure 1. Position the center bearing on the propeller shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5671 2. Install the J 37372 on the propeller shaft. 3. Using the J 37372 (1), install the center bearing on the propeller shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5672 Note: Failure to align the reference marks properly will cause a vibration the propeller shaft. 4. Position the yoke on the propeller shaft so that the reference marks are aligned properly. 5. Using a brass or hard rubber hammer, lightly tap the yoke on the propeller shaft. 6. Install the washer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Tighten the retaining nut by hand before tightening the retaining nut to the proper specifications. 7. Install the retaining nut and tighten to 167 Nm (123 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5673 8. Align the U-Joint to the reference marks on the propeller shaft and yoke. 9. Install the U-Joint to the yoke. 10. Remove the shop towels from the propeller shaft. 11. Install the propeller shaft in the vehicle. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications Drive/Propeller Shaft: Mechanical Specifications Fastener Tightening Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications > Page 5678 Drive/Propeller Shaft: Fluid Type Specifications Adhesives, Fluids, Lubricants, and Sealers Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5679 Drive/Propeller Shaft: Diagrams Driveline Disassembled Views Front Drive Propeller Shaft 1 - Universal Joint Spider Assembly 2 - Propeller Shaft Tube Assembly One-Piece Propeller Shaft 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 6 - Propeller Shaft Universal Joint 7 - Propeller Shaft Bearing Retainer 8 Propeller Shaft Bearing Retainer Bolt Two-Piece Propeller Shaft Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5680 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint and Bearing 4 - Propeller Shaft Tube 5 - Propeller Shaft Center Bearing 6 - Propeller Shaft Yoke 7 - Propeller Shaft Yoke Retaining Nut 8 - Propeller Shaft Universal Joint and Bearing 9 - Propeller Shaft Universal Joint Bearing Retaining Ring 10 Propeller Shaft Tube 11 - Propeller Shaft Universal Joint and Bearing 12 - Propeller Shaft Universal Joint Bearing Retaining Ring Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5681 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Two Piece Propeller Shaft Description There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is used to support the propeller shaft connection point, and help isolate the vehicle from vibration. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and slowing down each time the universal joint goes around. The vibration is the same as a person snapping a rope and watching the wave reaction flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other out. A total cancellation of vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft (See: Symptom Related Diagnostic Procedures/Symptoms - Propeller Shaft) in order to identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5684 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation (See: Description and Operation). Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: * Leaks * Noises * Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Diagnostic Information and Procedures/Diagnostic Starting Point - Vibration Diagnosis and Correction). Visual/Physical Inspection * Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Leak at Front Slip Yoke (See: Leak at Front Slip Yoke) * Universal Joint Noise (See: Universal Joint Noise) * Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise) * Knock or Clunk Noise (See: Knock or Clunk Noise) * Scraping Noise (See: Scraping Noise) * Squeak Noise (See: Squeak Noise) * Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed) Knock or Clunk Noise Knock or Clunk Noise Leak at Front Slip Yoke Leak at Front Slip Yoke Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5685 Ping, Snap, or Click Noise Ping, Snap, or Click Noise Scraping Noise Scraping Noise Shudder on Acceleration at Low Speed Shudder on Acceleration at Low Speed Squeak Noise Squeak Noise Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5686 Universal Joint Noise Universal Joint Noise Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement Front Propeller Shaft Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Mark the front U-joint to the pinion yoke on the front differential. 3. Mark the relationship of the rear U-joint to the transfer case drive flange. 4. Mark the relationship of the rear U-joint to the transfer case drive flange. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5689 5. Remove the retaining nuts and bolts from the drive flange. 6. Remove the clamps and retaining bolts from the front drive axle pinion flange. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5690 7. Remove the front propeller shaft from the vehicle. 8. Using tape and or a rubber band, wrap the front U-joint bearing caps to ensure the caps do not separate from the U-joint. Installation Procedure. 1. Remove the tape or rubber band from the front U-joint 2. Install the front propeller shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5691 3. Align the reference marks on the front U-joint. Note: When installing the retaining bolts, only tighten them finger tight to hold the front propeller shaft in position. 4. Install the front U-joint bolts and clamps. 5. Align the reference marks on the rear U-joint. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5692 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the propeller shaft to pinion flange bolts. * Tighten the bolts from the propeller shaft to the pinion flange 20 Nm (15 lbft). * Tighten the bolts for the front propeller U-joint clamps 20 Nm (15 lb ft). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5693 Drive/Propeller Shaft: Service and Repair One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement Removal Procedure 1. Place the transmission in neutral. 2. Release the park brake, if applied. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Mark the rear universal joint to the drive shaft flange. 5. Remove the retaining bolts and clamps. 6. Remove the propeller shaft from the pinion drive flange. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5694 7. Remove the propeller shaft from the transmission/transfer case. 8. Using tape or a rubber band, wrap the U-Joint bearing caps to ensure the bearing caps do not separate from the U-Joint. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5695 1. Remove the tape or rubber band from the U-Joint. 2. Install the propeller shaft in the transmission/transfer case. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5696 3. Align the propeller shaft with the reference marks on the pinion flange. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the clamps and retaining bolts and tighten the bolts to 20 Nm (15 lb ft). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5697 Drive/Propeller Shaft: Service and Repair Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement Removal Procedure Caution: Refer to Propeller Shaft Caution (See: Service Precautions). 1. Place transmission in neutral. 2. Release the park brake, if applied. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: The following service procedure will ensure the proper alignment of all U-Joint to the transmission, center bearing support and the rear drive axle pinion flange. 4. Rotate the propeller shafts so that all the external clips are aligned. 5. Mark the rear propeller shaft to the pinion drive flange, center bearing support, and transmission. 6. Remove the clamps and retaining bolts for the rear propeller shaft at the pinion drive flange and the center bearing. 7. Using tape or a rubber band, wrap the rear U-Joint bearing caps to ensure that they not separate from the U-Joint. 8. Remove the rear propeller shaft from the center bearing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5698 9. Remove the mounting bolts for the center bearing. 10. Remove the center bearing from the crossmember. 11. Remove the propeller shaft from the transmission. Installation Procedure 1. Align the reference marks on the propeller shaft to the transmission. 2. Install the propeller shaft in the transmission. 3. Install the center bearing to the crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the center bearing mounting bolts and tighten to 80 Nm (59 lb ft). 5. Rotate the propeller shaft so that the alignment marks and the pinion yoke are in alignment. 6. Remove the tape and or rubber band. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5699 7. Position the U-Joint in the pinion yoke. 8. Install the clamps and retaining bolts and tighten the bolts to 30 Nm (22 lb ft). 9. Double check the alignment marks to ensure that they are aligned properly 10. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 5700 Drive/Propeller Shaft: Tools and Equipment Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Special Tools * J 9522-3 U-Joint Bearing Separator * J 9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Caution: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. 6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 5704 2. Assemble one bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Note: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 5705 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications FLYWHEEL/FLEXPLATE Automatic Transmission Flex Plate Bolts First Pass............................................................................ ...........................................................................................................................20 Nm (15 lb ft) Second Pass........................................................................................................................................ ...........................................................50 Nm (37 lb ft) Final Pass........................................................ ............................................................................................................................................100 Nm (74 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement Flex Plate: Service and Repair Engine Flywheel Replacement Engine Flywheel Replacement Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Note: Note the position and direction of the engine flywheel before removal. 2. Remove the engine flywheel bolts. 3. Remove the engine flywheel. 4. Clean and inspect the engine flywheel. Refer to Automatic Transmission Flex Plate Cleaning and Inspection (). Installation Procedure Note: The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. 1. Install the engine flywheel to the crankshaft. 2. Apply threadlock to the threads of the flywheel bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 5711 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the engine flywheel bolts. * Tighten the bolts a first pass in sequence to 20 Nm (15 lb ft). * Tighten the bolts a second pass in sequence to 50 Nm (37 lb ft). * Tighten the bolts a final pass in sequence to 100 Nm (74 lb ft). 4. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 5712 Flex Plate: Service and Repair Automatic Transmission Flex Plate Replacement Automatic Transmission Flex Plate Replacement Removal Procedure 1. Remove the automatic transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) for the 4L60-E. Important: Note the position and direction of the engine flywheel before removal. 2. Remove the flywheel bolts. 3. Remove the flywheel. 4. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 5. Rotate the bolts clockwise to remove the spacer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 5713 6. Remove the spacer from the rear of the crankshaft, if applicable. Installation Procedure Note: * The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer, if applicable, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. * Certain applications (6.0L) require a spacer and longer bolts for proper flywheel position. 1. Install the spacer, if applicable, onto the rear of the crankshaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 5714 Note: Longer flywheel bolts must be used on applications using a flywheel spacer. 2. Install the flywheel and bolts to the crankshaft. 3. Apply threadlock to the threads of the flywheel bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the flywheel bolts. * Tighten the bolts (1-6) a first pass in sequence to 20 Nm (15 lb ft). * Tighten the bolts (1-6) a second pass in sequence to 50 Nm (37 lb ft). * Tighten the bolts (1-6) a final pass in sequence to 100 Nm (74 lb ft). 5. Install the automatic transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) for the 4L60-E. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications FLYWHEEL/FLEXPLATE Engine Flywheel bolts First pass in sequence to.................................................................................. ..............................................................................................20 Nm (15 lb ft) Second pass in sequence to.......................................................................................................................................... .................................50 Nm (37 lb ft) Final pass in sequence to.......................................................... ...................................................................................................................100 Nm (74 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 5718 Flywheel: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Note: Note the position and direction of the engine flywheel before removal. 2. Remove the engine flywheel bolts. 3. Remove the engine flywheel. 4. Clean and inspect the engine flywheel. Refer to Automatic Transmission Flex Plate Cleaning and Inspection (). Installation Procedure Note: The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. 1. Install the engine flywheel to the crankshaft. 2. Apply threadlock to the threads of the flywheel bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 5719 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the engine flywheel bolts. * Tighten the bolts a first pass in sequence to 20 Nm (15 lb ft). * Tighten the bolts a second pass in sequence to 50 Nm (37 lb ft). * Tighten the bolts a final pass in sequence to 100 Nm (74 lb ft). 4. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Fluid .................................................................................................................. ................................................. 2.2 liters (2.3 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 5725 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION FLUID SAE 75W-90, API AI-A or GL-3 GM Part No. U.S. 89021806, in Canada 89021807. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 5726 Fluid - M/T: Service and Repair Transmission Fluid Replacement Draining Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Clean away all dirt and debris from the transmission fluid drain plug area. 3. Position an appropriate container under the transmission. 4. Remove the transmission fluid drain plug and washer. Discard the washer. Allow the transmission fluid to drain into the container. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 5. Install the transmission fluid drain plug and NEW washer. Tighten the drain plug to 37 Nm (27 lb ft). 6. Remove the container used to catch the used transmission fluid from under the vehicle. Filling Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 5727 1. Clean away all dirt and debris from the transmission fluid fill plug area. 2. Remove the transmission fluid fill plug and washer. Discard the washer. 3. Fill the transmission to just below the bottom of the fill plug hole with the recommended fluid. Refer to Lubrication Specifications (See: Specifications/Fluid Type Specifications). 4. Install the transmission fluid fill plug and NEW washer. Tighten the fill plug to 37 Nm (27 lb ft). 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair Input Shaft: Service and Repair Input Shaft Bearing Retainer Replacement Removal Procedure 1. Drain the transmission fluid. Refer to Transmission Fluid Replacement (See: Service and Repair/Removal and Replacement/Transmission Fluid Replacement). 2. Remove the clutch actuator cylinder. Refer to Clutch Actuator Cylinder Replacement (See: Clutch/Clutch Hydraulic System/Clutch Slave Cylinder/Service and Repair). 3. Remove the input shaft bearing retainer bolts. Discard the bolts. 4. Remove the input shaft bearing retainer. 5. Clean and inspect the input shaft bearing retainer. Refer to Transmission Case Cleaning and Inspection (See: Service and Repair/Overhaul/Cleaning and Inspection/Transmission Case Cleaning and Inspection). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Page 5731 1. Apply a 3 mm (1/8 in) bead of sealant GM P/N 89020326 (Canadian P/N 89021188) to the input shaft bearing retainer. Note: Ensure the seal does not catch on the input shaft splines. 2. Position the input shaft bearing retainer to the transmission. 3. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads of the input shaft bearing retainer bolts if new bolts are not available. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the NEW input shaft bearing retainer bolts. Tighten the input shaft bearing retainer bolts to 17 Nm (13 lb ft). 5. Install the clutch actuator cylinder. Refer to Clutch Actuator Cylinder Replacement (See: Clutch/Clutch Hydraulic System/Clutch Slave Cylinder/Service and Repair). 6. Fill the transmission fluid. Refer to Transmission Fluid Replacement (See: Service and Repair/Removal and Replacement/Transmission Fluid Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Page 5732 Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Transmission Input Shaft Seal Replacement Seals and Gaskets: Service and Repair Transmission Input Shaft Seal Replacement Transmission Input Shaft Seal Replacement Tools Required J 45866 Input Shaft Seal Installer Removal Procedure 1. Remove the transmission input shaft bearing retainer. Refer to Input Shaft Bearing Retainer Replacement (See: Input Shaft/Service and Repair). 2. Using a hammer and a punch, remove the input shaft seal from the input shaft bearing retainer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Transmission Input Shaft Seal Replacement > Page 5737 1. Using the J 45866 and a hammer, install the input shaft seal into the input shaft bearing retainer. * The spring side of the seal goes toward the tool * Ensure the seal is installed square * The tool will install the seal to the correct depth 2. Install the transmission input shaft bearing retainer. Refer to Input Shaft Bearing Retainer Replacement (See: Input Shaft/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Transmission Input Shaft Seal Replacement > Page 5738 Seals and Gaskets: Service and Repair Transmission Housing Oil Seal Replacement - Rear Transmission Housing Oil Seal Replacement - Rear (RWD) Tools Required J 45868 RWD Output Shaft Seal Installer Removal Procedure 1. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 2. Using a suitable tool, pry the rear transmission housing oil seal from the transmission housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Transmission Input Shaft Seal Replacement > Page 5739 1. Using the J 45868 and a hammer, install the NEW rear transmission housing oil seal. 2. Check the transmission fluid level. Add if necessary. Refer to Transmission Fluid Replacement (See: Service and Repair/Removal and Replacement/Transmission Fluid Replacement). 3. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Sensor (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5744 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position switch (1). 2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5745 1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1), until the locking tabs (2) are fully engaged. 2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the following in order to adjust the clutch pedal position switch (1). 1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2. Depress the clutch pedal all the way to the floor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06) Shifter M/T: Service and Repair Shift Lever Assembly Replacement (w/o D06) Shift Lever Assembly Replacement (w/o D06) Removal Procedure 1. Pull upward on the front of the boot (3) in order to disengage the boot retainers (2) from the floor console (1). 2. Remove the set screw (1) from the shift lever (2). 3. Remove the shift lever assembly from the control lever. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06) > Page 5750 1. Install the shift lever assembly to the control lever, aligning the set screw threaded hole with the seat (3) 2. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488) to the shift lever set screw threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the shift lever set screw and tighten to 25 Nm (18 lb ft). 4. Position the boot tabs (4) under the rear of the console opening. 5. Push downward on the front of the boot (3) in order to engage the boot retainers (2) with the floor console (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06) > Page 5751 Shifter M/T: Service and Repair Shift Lever Assembly Replacement (D06) Shift Lever Assembly Replacement (D06) Removal Procedure 1. Pull upward on the boot (1) in order to disengage the bezel retainers (2) from the console (3). 2. Remove the set screw (1) from the shift lever (2). 3. Remove the shift lever assembly from the control lever. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Lever Assembly Replacement (w/o D06) > Page 5752 1. Install the shift lever assembly to the control lever, aligning the set screw threaded hole with the seat (3). 2. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488) to the shift lever set screw threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the shift lever set screw and tighten to 25 Nm (18 lb ft). 4. Push downward on the bezel in order to engage the bezel retainers (2) with the console (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair Shift Boot: Service and Repair Control Lever and/or Boot Replacement Removal Procedure 1. Remove the shift lever assembly. Refer to Shift Lever Assembly Replacement (w/o D06) (See: Shifter M/T/Service and Repair/Shift Lever Assembly Replacement (w/o D06))Shift Lever Assembly Replacement (D06) (See: Shifter M/T/Service and Repair/Shift Lever Assembly Replacement (D06)). 2. Remove the console (w/o D06 only). Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). 3. Remove the control lever boot screws. 4. Tilt and remove the control lever boot from the control lever. 5. Shift the transmission into neutral (N). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > Page 5757 6. Remove the control lever housing assembly bolts. 7. Remove the control lever housing assembly and gasket. 8. Mask off the control lever housing opening, in order to prevent foreign objects from entering the transmission. 9. Disassemble the control lever housing if necessary. Refer to Shift Control Housing Disassemble (See: Service and Repair/Overhaul/Disassembly/Shift Control Housing Disassemble). Installation Procedure 1. Assemble the control lever housing if previously disassembled. Refer to Shift Control Housing Assemble (See: Service and Repair/Overhaul/Assembly/Shift Control Housing Assemble). 2. Remove the masking from the control lever opening and ensure the sealing surface is clean and dry. 3. Place the control lever gasket on to the transmission. 4. Position the control lever housing assembly to the control lever assembly opening, aligning the bushing with the internal shift control lever. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > Page 5758 5. Install the control lever housing assembly bolts and tighten to 20 Nm (15 lb ft). 6. Slide the boot into position over the control lever. Note: Ensure the carpet is not between the boot and the floor panel. 7. Tilt the boot in order to seat to the floor. 8. Install the control lever boot screws and tighten to 2.5 Nm (22 lb in). 9. Install the console (w/o D06 only). Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). 10. Install the shift lever assembly. Refer to Shift Lever Assembly Replacement (w/o D06) (See: Shifter M/T/Service and Repair/Shift Lever Assembly Replacement (w/o D06))Shift Lever Assembly Replacement (D06) (See: Shifter M/T/Service and Repair/Shift Lever Assembly Replacement (D06)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) Transmission Mount: Service and Repair Transmission Mount Replacement (RPO Z71) Transmission Mount Replacement (RPO Z71) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission jack. 3. Remove the two nuts (1) securing the transmission mount to the transmission support. 4. Raise the transmission off of the transmission support. 5. Remove the mount to transmission bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5763 6. Remove the mount spacer. Installation Procedure 1. Install the mount spacer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5764 2. Install the transmission mount to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the mount to transmission bolts and tighten to 55 Nm (41 lb ft). 4. Lower the transmission and install the two nuts (1) securing the transmission mount to the transmission support. Tighten the nuts to 57 Nm (42 lb ft). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5765 Transmission Mount: Service and Repair Transmission Mount Replacement (RPO Z85 and ZQ8) Transmission Mount Replacement (RPO Z85 and ZQ8) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission jack. 3. Remove the two nuts (1) securing the transmission mount to the transmission support. 4. Raise the transmission off of the transmission support. 5. Remove the mount to transmission bolts. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement (RPO Z71) > Page 5766 1. Install the transmission mount to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the mount to transmission bolts and tighten to 55 Nm (41 lb ft). 3. Lower the transmission and install the two nuts (1) securing the transmission mount to the transmission support. Tighten the nuts to 57 Nm (42 lb ft). 4. Remove the transmission jack. 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 5772 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 5773 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Inside the Transmission Components (M30) 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5779 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30) Description Location Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5783 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5784 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5785 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5786 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5787 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Sensor (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5798 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position switch (1). 2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 5799 1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1), until the locking tabs (2) are fully engaged. 2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the following in order to adjust the clutch pedal position switch (1). 1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2. Depress the clutch pedal all the way to the floor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components 1 - X275 2 - Automatic Transmission Shift Lock Control Solenoid Connector 3 - Body Harness 4 Accelerator Pedal Position (APP) Sensor Connector 5 - Accelerator Pedal 6 - Accelerator Pedal Position (APP) Sensor 7 - Automatic Transmission Shift Lock Control Solenoid (M30) 8 - Ignition Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5809 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5810 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5811 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5925 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5926 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5955 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5956 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5957 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5958 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5959 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5990 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5991 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5992 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5993 Transmission/Transaxle/Service and Repair/Removal and Replacement). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6171 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6172 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6173 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6174 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6175 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 4. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 5. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6176 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 6. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 7. Install the TCC PWM solenoid to the control valve body. 8. Install the TCC PWM solenoid retainer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6177 9. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 10. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 11. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 12. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 15. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Electric Motor Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine protection shield (EPS). Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Remove the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 6182 4. Remove the electric motor actuator. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: Apply TEFLON(TM) tape to the threads of the electric actuator motor before installation. 1. Install the electric motor actuator and tighten to 22 Nm (16 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 6183 2. Install the electrical connector. 3. Install the EPS. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 6189 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 6190 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Inside the Transmission Components (M30) 36 - Vehicle Speed Sensor (VSS) 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (3-2 SS) Valve Assembly 396 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6196 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (M30) Description Location Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Left Side of the Transmission Components (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6200 1 - Automatic Transmission 2 - Park/Neutral Position (PNP) Switch Rear of the Transmission Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6201 1 - Park/Neutral Position (PNP) Switch (M30) 2 - Heated Oxygen Sensor (HO2S) 2 3 - Vehicle Speed Sensor (VSS) 4 - Transfer Case Neutral Switch (4WD) 5 - Transfer Case 2/4 Wheel Indicator Switch (4WD) 6 - Transfer Case Encoder Motor (4WD) 7 - Transfer Case Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6202 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6203 Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6204 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Sensor (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 6215 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Disconnect the electrical connector (2) from the clutch pedal position switch (1). 2. Push the clutch pedal position switch retaining plate locking tabs (2) inward toward each other to release. 3. Remove the clutch pedal position switch (3) from the clutch pedal assembly (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Diagrams > Page 6216 1. Slide the clutch pedal position switch (3) with retaining plate (2) into the clutch pedal bracket (1), until the locking tabs (2) are fully engaged. 2. Connect the electrical connector (2) to the clutch pedal position switch (1). 3. Complete the following in order to adjust the clutch pedal position switch (1). 1. Push the switch fully into the bracket, allowing the switch to ratchet in the retaining plate. 2. Depress the clutch pedal all the way to the floor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Service and Repair Acceleration/Deceleration Sensor: Service and Repair Longitudinal Accelerometer Replacement Removal Procedure 1. Remove the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). 2. Access the sensor through service slit provided in the carpet. 3. Disconnect the longitudinal accelerometer electrical connector. 4. Remove the nuts (1) from the longitudinal accelerometer. 5. Remove the longitudinal accelerometer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 6222 1. Install the longitudinal accelerometer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the longitudinal accelerometer nuts (1) and tighten to 9 Nm (80 lb in). 3. Connect the longitudinal accelerometer electrical connector. 4. Install the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6227 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6228 Electronic Brake Control Module: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6229 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6230 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6231 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6232 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6233 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition switch to the OFF position. 2. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair). 3. Remove the electronic brake control module (EBCM) bolts (1). Discard the bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6234 4. Carefully separate the EBCM (1) from the BPMV. 5. Remove the 12 EBCM to BPMV seals (2). Installation Procedure 1. Carefully install the EBCM (1) and the 12 seals (2) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Do not reuse the EBCM bolts. Install new bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6235 2. Install new EBCM bolts (1) and tighten to 2 Nm (18 lb in). 3. Install the EBCM/BPMV assembly to the vehicle. Refer to Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly Antilock Brakes/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition switch to the OFF position. 2. Disconnect the electronic brake control module (EBCM) electrical connector. 3. Clean the area around the brake pipe fittings and the EBCM and the brake pressure modulator valve (BPMV) mating surfaces of any accumulated dirt and debris. 4. Disconnect the RF brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6239 5. Disconnect the RR brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 6. Disconnect the LR brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6240 7. Disconnect the LF brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 8. Disconnect the master cylinder primary brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6241 9. Disconnect the master cylinder secondary brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 10. Remove the EBCM/BPMV assembly bracket nuts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6242 11. Remove the EBCM/BPMV assembly (1). 12. If necessary, remove the BPMV bracket bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6243 13. If necessary, remove the bracket (1) from the BPMV. 14. Remove the EBCM. Refer to Electronic Brake Control Module Replacement (See: Electronic Brake Control Module/Service and Repair). Installation Procedure 1. Install the EBCM. Refer to Electronic Brake Control Module Replacement (See: Electronic Brake Control Module/Service and Repair). 2. If removed, install the bracket (1) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6244 3. If removed, install the BPMV bracket bolts (1) and tighten to 11 Nm (97 lb in). 4. Install the EBCM/BPMV assembly (1) to the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6245 5. Install the EBCM/BPMV assembly bracket nuts (1) and tighten to 9 Nm (80 lb in). Connect the master cylinder secondary brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 32 Nm (24 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6246 Connect the master cylinder primary brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 32 Nm (24 lb ft). Connect the LF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6247 Connect the LR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). 6. Connect the RR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6248 7. Connect the RF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). 8. Connect the EBCM electrical connector. 9. Perform the Antilock Brake System Automated Bleed Procedure (See: Brake Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 6252 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 6253 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 6254 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 6255 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 6256 Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (2WD) (JL4) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams Traction Control Switch: Diagrams Component Connector End Views Traction Control Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Page 6260 Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Wheel Speed Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6265 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6266 Wheel Speed Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6267 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6268 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6269 Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Front Wheel Knuckle Components 1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Left Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 6270 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front Wheel Speed Sensor (WSS) - Right Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 6271 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Within the engine compartment, disconnect the wheel speed sensor electrical connector (1). 2. Release the wheel speed sensor harness connector from the wheelhouse. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 5. Release the wheel speed sensor harness clips (1) from the suspension upper control arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6274 6. Release the wheel speed sensor harness grommet (1) from the mounting bracket. 7. Remove the wheel speed sensor harness bracket bolt (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6275 8. Thoroughly clean the wheel speed sensor mounting area of the steering knuckle of any dirt and debris. 9. Remove the wheel speed sensor bolt (1). Note: Do not pry or lever against the wheel speed sensor to remove. 10. Carefully remove the wheel speed sensor from the suspension knuckle by pulling straight upward. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6276 1. Install the wheel speed sensor to the suspension knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 8 Nm (71 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6277 3. Install the wheel speed sensor harness bracket bolt (1) and tighten to 9 Nm (80 lb in). 4. Install the wheel speed sensor harness grommet (1) to the mounting bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6278 5. Install the wheel speed sensor harness clips (1) to the suspension upper control arm. 6. Install the wheel speed sensor harness connector to the wheelhouse. 7. Connect the wheel speed sensor electrical connector (1). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6279 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the wheel speed sensor bolts (1). 3. Remove the wheel speed sensor (1) from the drum brake backing plate by carefully pulling straight outward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6280 4. Release the wheel speed sensor harness retainers (1) on the rear park brake cable. Release the harness from the retainers. 5. Disconnect the wheel speed sensor electrical connector (1). 6. Release the electrical connector and harness retainer (2) from the frame. 7. Remove the wheel speed sensor assembly. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6281 1. Position the wheel speed sensor assembly to the vehicle. 2. Connect the wheel speed sensor electrical connector (1). 3. Install the electrical connector and harness retainer (2) to the frame. 4. Position the wheel speed sensor harness to the retainers (1) on the rear park brake cable. 5. Fasten the wheel speed sensor harness retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6282 6. Install the wheel speed sensor (1) to the drum brake backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the wheel speed sensor bolts (1) and tighten to 17 Nm (13 lb ft). 8. Lower the vehicle. 9. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6286 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6287 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6288 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6289 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6290 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (2WD) (JL4) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6291 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel Brake Bleeding: Customer Interest Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6300 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6301 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel Brake Bleeding: All Technical Service Bulletins Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6307 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6308 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6314 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6315 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6316 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6321 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6322 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6323 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6324 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6325 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6326 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 6331 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6332 Brake Bleeding: By Symptom Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6333 List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6334 Disclaimer Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6335 Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6336 For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6337 Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Other Service Bulletins for Brake Bleeding: > Page 6338 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure Antilock Brake System Automated Bleed Procedure Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: ). 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6341 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6342 Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Pressure Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent. Add GM approved brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6343 install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling) 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure (See: ). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6344 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement) * Wheel Cylinder Replacement (See: Drum Brake System/Wheel Cylinder/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement) * Wheel Cylinder Replacement (See: Drum Brake System/Wheel Cylinder/Service and Repair) , if equipped * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6345 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Remove the steering column. Refer to Steering Column Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Replacement). 2. Disconnect the stoplamp switch electrical connectors. 3. Remove the brake booster pushrod retainer (1). 4. Remove the brake booster pushrod clevis pin (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 6349 5. Remove the upper brake pedal bracket bolts (1). 6. Remove the power vacuum brake booster nuts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 6350 7. Remove the brake pedal assembly (1). Installation Procedure 1. Install the brake pedal assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 6351 2. Install the power vacuum brake booster nuts (1) and tighten to 20 Nm (15 lb ft). 3. Install the upper brake pedal bracket bolts (1) and tighten to 27 Nm (20 lb ft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 6352 4. Install the brake booster pushrod clevis pin (1) to the pushrod and the brake pedal. 5. Install the brake booster pushrod retainer (1). 6. Connect the stoplamp switch electrical connectors. 7. Install the steering column. Refer to Steering Column Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement Brake Caliper: Service and Repair Brake Caliper Replacement Brake Caliper Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Note: Do not reuse the brake hose fitting gaskets. 3. Remove the brake hose fitting bolt (1), the brake hose fitting gaskets (2), and the brake hose fitting (3) from the brake caliper. Cap the brake hose fitting to prevent brake fluid loss and contamination. 4. Discard the brake hose fitting gaskets. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6359 5. Remove the brake caliper guide pin bolts (1). 6. Remove the brake caliper (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6360 1. Install the brake caliper (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper guide pin bolts (1) and tighten to 64Nm (47 lb ft). Note: Install new brake hose fitting gaskets. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6361 3. Assemble the brake hose fitting bolt (1) and new brake hose fitting gaskets (2) to the brake hose fitting (3). 4. Install the brake hose assembly to the brake caliper and tighten the fitting bolt to 40 Nm (30 lb ft). 5. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6362 Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Without disconnecting the front brake hose, remove the brake caliper and support with heavy mechanics wire or equivalent. Refer to Brake Caliper Replacement (See: Brake Caliper Replacement). 4. Remove the 2 brake caliper bracket bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6363 5. Remove the brake caliper bracket. 6. Inspect the disc brake hardware for damage and replace, if necessary. Refer to Disc Brake Mounting and Hardware Inspection (See: Testing and Inspection/Component Tests and General Diagnostics). Installation Procedure 1. Install the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6364 2. Install the 2 brake caliper bracket bolts and tighten to 180 Nm (133 lb ft). 3. Install the brake caliper. Refer to Brake Caliper Replacement (See: Brake Caliper Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum Pad Thickness ............................................................................................................................... 1.40 mm (0.055 in) from the mounting plates. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 6368 Brake Pad: Testing and Inspection Brake Pad Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). * Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle. * If replacement is necessary, always replace disc brake pads in axle sets. * Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the leading edge of the disc brake pads. * Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely. The disc brake pad wear should be approximately even per axle set. * Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation. * Replace the disc brake pads when the friction surface (3) is worn to within 1.40 mm (0.055 in) of the mounting plates. * Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads. * Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance. * Replace the disc brake pads if any have separated from the mounting plates. * Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement Brake Pad: Service and Repair Brake Pads Replacement Brake Pads Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the master cylinder reservoir. 2. If the brake fluid is midway between the maximum full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid is higher than midway between the maximum full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outboard brake pad. 7. Tighten the C-clamp evenly until the caliper pistons are compressed into the caliper bore. 8. Remove the lower brake caliper guide pin bolt (1). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6371 9. Pivot the brake caliper (1) upward and support with heavy mechanics wire or equivalent. 10. Remove the outer brake pad (1). 11. Remove the inner brake pad. (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6372 12. If installing new disc brake pads, remove and discard the brake pad shims (1). 13. Thoroughly clean the brake caliper bracket mating surfaces and, if reusing the brake pads, clean the brake pad shims with denatured alcohol and allow to dry. Installation Procedure 1. If installing new disc brake pads, install new brake pad shims (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6373 2. Install the outer brake pad (1). 3. Install the inner brake pad. (2). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Pivot the brake caliper (1) downward and position to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6374 5. Install the lower brake caliper guide pin bolt (1) and tighten to 64 Nm (47 lb ft). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 9. Slowly release the brake pedal. 10. Wait 15 seconds then repeat steps 8-9 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and the brake pads. 11. Fill the master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 12. Burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad and Rotor Burnishing). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6375 Brake Pad: Service and Repair Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6380 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6381 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6382 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6383 WARRANTY INFORMATION Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6384 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6385 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6386 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6387 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6388 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6389 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6390 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6391 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6392 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6393 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 6394 Brake Rotor/Disc: Specifications BRAKE ROTOR/DISC Brake Rotor Discard Thickness............................................................................................................ ........................................................27.5 mm (1.08 in) Brake Rotor Maximum Allowable Thickness Variation...........................................................................................................................0.050 mm (0.002 in) Lateral Runout...................................................................................................................... ....................................................................0.125 mm (0.005 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Surface and Wear Inspection Brake Rotor/Disc: Testing and Inspection Brake Rotor Surface and Wear Inspection Brake Rotor Surface and Wear Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Brake Pads Replacement (See: Brake Pad/Service and Repair/Brake Pads Replacement). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. * Cracks and/or heat spots * Excessive blueing discoloration 4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor requires refinishing or replacement. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Surface and Wear Inspection > Page 6397 Brake Rotor/Disc: Testing and Inspection Brake Rotor Thickness Measurement Brake Rotor Thickness Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Clean the brake pad lining contact surface of the brake rotor with denatured alcohol or an equivalent brake cleaner. 2. Using a micrometer calibrated in ten-thousands of an inch, measure and record the lowest thickness of the brake rotor at 4 or more points, equally spaced around the rotor. Ensure that the measurements are only taken within the brake pad lining contact area and that the micrometer is positioned the same distance from the outside edge of the rotor for each measurement. 3. Compare the lowest thickness measurement recorded to the following specifications: Brake rotor discard thickness 27.5 mm (1.08 in). 4. If the lowest thickness measurement of the brake rotor is above the brake rotor discard thickness specification; the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 5. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification; the rotor requires replacement. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Rotor Refinishing Special Tools CH-47661 On-Vehicle Brake Lathe Note: Do NOT refinish the brake rotors in order to correct any of the following complaints: * Growl or squeal brake noise * Premature brake lining wear * Cosmetic or superficial corrosion of the rotor braking surface * Rotor discoloration Refinish the brake rotors ONLY when 1 or more of the following conditions exist: * Groove depth in excess of specification * Severe scoring of the rotor braking surface * Brake pulsation caused by the following: - Lateral runout in excess of specification - Brake rotor thickness variation in excess of specification - Corrosion or pitting that is deeper than the rotor braking surface 1. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the brake rotor. Replace the brake rotor. 2. Use the CH-47661 to refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions. Note: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 3. After machining the rotor, use 120 grit aluminum oxide sandpaper and a non-directional rotor finisher, if available, in order to create a non-directional braking surface. 4. Clean the braking surfaces with GM P/N 12377981 (Canadian P/N 10953463) or equivalent, brake parts cleaner. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6400 Brake Rotor/Disc: Removal and Replacement Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Replacement Brake Rotor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub Replacement (See: Maintenance/Wheels and Tires/Wheel Bearing/Service and Repair). Note: Support the brake rotor assembly on wooden blocks to prevent damage to brake rotor friction surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6401 4. While supporting the brake rotor assembly, remove the 6 wheel hub bolts. 5. Separate the wheel hub from the brake rotor. 6. Clean the wheel hub and brake rotor mating surfaces to remove any debris or corrosion. Installation Procedure Note: Support the brake rotor assembly on wooden blocks to prevent damage to brake rotor friction surface. 1. Position the wheel hub to the brake rotor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Use only hand tools to install the wheel hub bolts. Note: Ensure the wheel hub and brake rotor are properly mated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6402 2. While supporting the brake rotor assembly, install the 6 wheel hub bolts and, using only hand tools, tighten the bolts to 120 Nm (89 lb ft). 3. Install the wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub Replacement (See: Maintenance/Wheels and Tires/Wheel Bearing/Service and Repair). 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Rear Brake Backing Plate Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement). 3. Remove the park brake cable from the rear brake backing plate. Refer to Parking Brake Rear Cable Replacement - Left Side (See: Parking Brake System/Parking Brake Cable/Service and Repair/Removal and Replacement/Parking Brake Rear Cable Replacement - Left Side) or Parking Brake Rear Cable Replacement - Right Side (See: Parking Brake System/Parking Brake Cable/Service and Repair/Removal and Replacement/Parking Brake Rear Cable Replacement - Right Side). 4. Remove the wheel cylinder. Refer to Wheel Cylinder Replacement (See: Wheel Cylinder/Service and Repair). 5. Remove the rear axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Remove the rear brake backing plate bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 6407 7. Remove the rear brake backing plate (1). Installation Procedure 1. Install the rear brake backing plate (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 6408 2. Install the rear brake backing plate bolts (1) and tighten to 135 Nm (100 lb ft). 3. Install the rear axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 4. Install the wheel cylinder. Refer to Wheel Cylinder Replacement (See: Wheel Cylinder/Service and Repair). 5. Install the park brake cable to the rear brake backing plate. Refer to Parking Brake Rear Cable Replacement - Left Side (See: Parking Brake System/Parking Brake Cable/Service and Repair/Removal and Replacement/Parking Brake Rear Cable Replacement - Left Side) or Parking Brake Rear Cable Replacement - Right Side (See: Parking Brake System/Parking Brake Cable/Service and Repair/Removal and Replacement/Parking Brake Rear Cable Replacement - Right Side). 6. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications BRAKE DRUM Maximum Allowable Diameter.............................................................................................................. ................................................296.5 mm (11.673 in) Maximum Allowable Radial Runout................... .......................................................................................................................................0.15 mm (0.006 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement Brake Drum: Testing and Inspection Brake Drum Diameter Measurement Brake Drum Diameter Measurement 1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an equivalent brake cleaner. 2. Using a brake drum micrometer calibrated in thousands of an inch, measure and record the largest diameter of the brake drum at 4 or more points, equally spaced around the drum. Ensure that the measurements are only taken within the brake shoe lining contact area and that the micrometer is positioned the same distance from the outside edge of the drum for each measurement. 3. The maximum allowable diameter : Maximum allowable measurement 296.5 mm (11.673 in) 4. If the largest diameter measurement of the brake drum is less than the maximum allowable diameter, the drum may be able to be resurfaced, depending upon surface and wear conditions which may be present. 5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable measurement, the drum requires replacement. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement > Page 6414 Brake Drum: Testing and Inspection Brake Drum Surface and Wear Inspection Brake Drum Surface and Wear Inspection Special Tools J 8001 Dial Indicator Set, or equivalent Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. With the brake drum removed, clean the braking (friction) surface of the brake drum with denatured alcohol or an equivalent approved brake cleaner. 2. Inspect the braking surface of the brake drum for the following Braking Surface Conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc; heavy surface rust and/or pitting must be removed by refinishing the drum. * Cracks and/or heat spots * Excessive blueing discoloration * Missing balance weights 3. If the braking surface of the brake drum exhibits one or more of the Braking Surface Conditions, the drum requires refinishing or replacement. 4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any grooves present on the drum braking surface. Ensure that the measurements are only taken within the brake shoe lining contact area. 5. Compare the groove, scoring, depth recorded to the following specification: Brake drum maximum allowable scoring 1.5 mm (0.06 in). 6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present, the drum requires refinishing or replacement. 7. Mount the brake drum on a brake lathe. 8. Mount a dial indicator, J 8001 or equivalent, and position the indicator button so it contacts the braking surface of the brake drum at a 90 degree angle, approximately 19 mm (0.75 in) from the drum's outer edge. 9. Measure and record the radial runout of the brake drum. 1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial. 2. Rotate the drum until the highest reading is displayed on the dial. 10. Compare the radial runout of the brake drum to the following specification: Brake drum maximum allowable radial runout 0.15 mm (0.006 in). 11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures Brake Drum: Procedures Brake Drum Refinishing Tools Required J 41013 Rotor Resurfacing Kit Important: Do NOT refinish the brake drums in order to correct any of the following complaints: * Brake noise (growl/squeal) * Premature brake lining wear * Cosmetic or superficial corrosion of the drum braking surface * Drum discoloration Refinish the brake drums ONLY when 1 or more of the following conditions exist: * Severe scoring of the drum braking surface (groove depth in excess of specification) * Brake pulsation caused by the following: - Brake drum out of round (runout in excess of specification) - Corrosion or pitting that is deeper than the drum braking surface 1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the brake drum exceeds the brake drum maximum refinish diameter, do NOT refinish the brake drum. Replace the brake drum. 2. Use the J 41013 or an equivalent tool in order to THOROUGHLY clean the rust from the brake drum flange. 3. Refinish the brake drum. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 4. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a non-directional braking surface. 5. Clean the braking surfaces with GM P/N 12377981 (Canadian P/N 10953463) or equivalent brake parts cleaner. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 6417 Brake Drum: Removal and Replacement Brake Drum Replacement Special Tools J-42450-A - Wheel Hub Resurfacing Kit Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove and discard the brake drum retainers (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 6418 4. Remove the brake drum (1). 5. If the brake drum is difficult to remove, retract the brake shoes using the following procedure: 1. Remove the rubber adjuster access hole plug located below the wheel cylinder on the rear brake backing plate. 2. Insert a small, flat bladed tool through the access hole at a slight downward angle to contact the adjuster lever. 3. Insert a second small, flat bladed tool straight into the access hole just above the first tool to contact the adjuster teeth. 4. While applying slight inward pressure on the first tool, rotate the adjuster counter clockwise using the second tool against the adjuster teeth. 5. Continue to rotate the adjuster until the brake shoes are retracted and the brake drum can be removed. 6. Using the J-42450-A - Wheel Hub Resurfacing Kit , clean the brake drum and rear axle flange mating surfaces of any accumulated dirt or corrosion. Installation Procedure 1. Adjust the rear drum brakes. Refer to Drum Brake Adjustment (See: Adjustments). 2. Install the brake drum (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 6419 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications BRAKE SHOE Bonded Lining....................................................................................................................................... .....................................................0.72 mm (0.028 in) Riveted Shoe ................................................... ....................................................................................................................................... 0.76 mm (0.029 in)* *Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.029 in) of any rivet head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6423 Brake Shoe: Testing and Inspection Brake Shoe Inspection Inspect the linings every 9,650 km (6,000 mi) and any time the wheels are removed (tire rotation, etc.). Inspect the lining for wear by removing the brake drum. Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Always replace shoe and lining assemblies as a complete axle set. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6424 Brake Shoe: Service and Repair Brake Shoe Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 2. Remove the brake shoe adjuster spring (1). 3. Remove the brake shoe adjuster lever (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6425 4. Carefully spread the top of the brake shoes away from the wheel cylinder and remove the brake shoe adjuster assembly (1). 5. Remove the brake shoe hold down springs and cups by compressing the springs inward and rotating the cups 1/4 turn. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6426 6. Rotate the forward brake shoe (1) toward the rear axle flange. 7. Remove the brake shoe lower retaining spring (2). 8. Remove the forward brake shoe (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6427 9. Remove the brake shoe upper return spring (1). 10. Release the park brake cable fitting from the brake shoe park brake apply lever. 11. Remove the rear brake shoe and park brake lever assembly (2) Installation Procedure 1. Clean the rear brake backing plate brake shoe contact points. 2. Apply a light coat of high temperature silicone brake lubricant to the rear brake backing plate brake shoe contact points. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6428 3. Install the park brake cable fitting to the brake shoe park brake apply lever. 4. Install the brake shoe upper return spring (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6429 5. Install the forward brake shoe (1). 6. Rotate the forward brake shoe (1) toward the rear axle flange. 7. Install the brake shoe lower retaining spring (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6430 8. Install the brake shoe hold down springs and cups by compressing the springs inward and rotating the cups 1/4 turn. 9. Carefully spread the top of the brake shoes away from the wheel cylinder and install the brake shoe adjuster assembly (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6431 10. Install the brake shoe adjuster lever (1). 11. Install the brake shoe adjuster spring (1). 12. Adjust the rear brake shoes. Refer to Drum Brake Adjustment (See: Adjustments). 13. Install the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove the rear brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and Repair). 2. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the brake pipe fitting and plug the wheel cylinder inlet port to prevent brake fluid loss and contamination. 3. Remove the wheel cylinder bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Page 6435 4. Remove the wheel cylinder (1). Installation Procedure 1. Install the wheel cylinder (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Page 6436 2. Install the wheel cylinder bolts (1) and tighten to 18 Nm (13 lb ft). 3. Connect the brake pipe fitting (1) to the wheel cylinder and tighten to 19 Nm (14 lb ft). 4. Install the rear brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and Repair). 5. Bleed the wheel cylinder. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes Brake Pedal Spongy/Increased Pedal Travel Brake Bleeding: Customer Interest Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes Brake Pedal Spongy/Increased Pedal Travel > Page 6446 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes Brake Pedal Spongy/Increased Pedal Travel > Page 6447 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel Brake Bleeding: All Technical Service Bulletins Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6453 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6454 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6455 Brake Bleeding: By Symptom Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6456 List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6457 Disclaimer Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6458 Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6459 For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-05-25-003 Date: 090921 Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6460 Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6461 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure Antilock Brake System Automated Bleed Procedure Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: ). 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6464 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6465 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Pressure Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent. Add GM approved brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6466 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , or equivalent, from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling) 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure (See: ). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6467 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Brake Caliper Replacement) * Wheel Cylinder Replacement (See: Wheel Cylinder/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Brake Caliper Replacement) * Wheel Cylinder Replacement (See: Wheel Cylinder/Service and Repair) , if equipped * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement Brake Caliper: Service and Repair Brake Caliper Replacement Brake Caliper Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Note: Do not reuse the brake hose fitting gaskets. 3. Remove the brake hose fitting bolt (1), the brake hose fitting gaskets (2), and the brake hose fitting (3) from the brake caliper. Cap the brake hose fitting to prevent brake fluid loss and contamination. 4. Discard the brake hose fitting gaskets. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6473 5. Remove the brake caliper guide pin bolts (1). 6. Remove the brake caliper (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6474 1. Install the brake caliper (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper guide pin bolts (1) and tighten to 64Nm (47 lb ft). Note: Install new brake hose fitting gaskets. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6475 3. Assemble the brake hose fitting bolt (1) and new brake hose fitting gaskets (2) to the brake hose fitting (3). 4. Install the brake hose assembly to the brake caliper and tighten the fitting bolt to 40 Nm (30 lb ft). 5. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6476 Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Without disconnecting the front brake hose, remove the brake caliper and support with heavy mechanics wire or equivalent. Refer to Brake Caliper Replacement (See: Brake Caliper Replacement). 4. Remove the 2 brake caliper bracket bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6477 5. Remove the brake caliper bracket. 6. Inspect the disc brake hardware for damage and replace, if necessary. Refer to Disc Brake Mounting and Hardware Inspection (See: Disc Brake System/Testing and Inspection/Component Tests and General Diagnostics). Installation Procedure 1. Install the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 6478 2. Install the 2 brake caliper bracket bolts and tighten to 180 Nm (133 lb ft). 3. Install the brake caliper. Refer to Brake Caliper Replacement (See: Brake Caliper Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications HYDRAULIC BRAKE SYSTEM DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6486 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6487 Brake Fluid Level Sensor/Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6488 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6489 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6490 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6491 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Removal Procedure 1. Remove the electrical connector from the sensor. 2. Using a pair of needle nose pliers bend on a 90 degree angle, release the retaining clip. 3. Remove the sensor from the master cylinder. Installation Procedure 1. Install the fluid sensor in the master cylinder. Make sure that the sensor is fully seated. 2. Install the electrical connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405 . * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6496 Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6497 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6498 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6499 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6500 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6501 Brake Hose/Line: Service and Repair Front Brake Hose Replacement Front Brake Hose Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Clean all dirt and foreign material from the brake hoses and the brake pipes. 4. Using a backup wrench on the brake pipe fitting, disconnect the brake pipe from the brake hose. Note: Install a plug or cap in the brake pipe fitting in order to prevent fluid loss and contamination. 5. Disconnect the brake pipe fitting from the brake hose at the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6502 Note: Inspect the condition of the retaining clip. If the retaining clip is flattened or damaged, discard and replace with new. 6. Remove the front brake hose retaining clip at the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6503 7. Remove the bolt and gaskets from the brake caliper. 8. Remove the brake hose from the brake caliper. 9. Remove the copper gaskets from the brake hose bolt. These gaskets may stick to the brake caliper or the brake hose bolt. Installation Procedure Note: DO NOT reuse the old copper gaskets. Always use NEW metal copper gaskets. 1. Install the copper gaskets on the brake hose. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper bolt to the brake caliper and tighten the bolt to 40 Nm (32 lb ft). 3. Remove the plug or cap from the exposed brake pipe fitting. 4. Install the brake hose to the brake pipe. Note: Ensure that the brake hose is not twisted and does not come in contact with any of the suspension components. 5. Using a backup wrench on the brake pipe fitting, tighten the brake hose fitting to 17 Nm (13 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6504 Note: Ensure that the retaining clip is properly seated. 6. Install the new brake pipe retaining clip. 7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6505 Brake Hose/Line: Service and Repair Rear Brake Hose Replacement Rear Brake Hose Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: Inspect the condition of the retaining clip. If the retaining clip is flatten or damaged, discard and replace with new. 2. Remove the retaining clip from the mounting bracket. 3. Using a backup wrench, remove the brake line from the brake hose. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6506 Note: Install a rubber cap or plug to the exposed brake pipe fitting in order to prevent brake fluid loss and contamination. 4. Install a rubber cap or plug in the brake line. 5. Remove the brake line to the left wheel cylinder. 6. Remove the brake line to the right wheel cylinder. 7. Install a rubber cap or plug in the brake lines. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6507 8. Remove the mounting bolt for the brake hose. 9. Remove the rear brake hose. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the mounting bolt to the brake hose or brake lines, always finger-tighten the bolt before tightening to specification. 1. Install the brake line to the brake hose and tighten the mounting bolt to 17 Nm (13 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6508 2. Install the new retaining clip for the rear brake hose. 3. Position the rear brake hose on the mounting bracket. Note: When installing the mounting bolt to the brake hose or brake lines, always finger-tighten the bolt before tightening to specification. 4. Install the mounting bolt. 5. Remove the rubber plug or cap from the left brake line to the brake hose. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6509 Note: When installing the brake hose or brake line fittings, always finger-tighten the fitting before tightening to specification. 6. Install the left brake line to the brake hose and tighten the fitting to 19 Nm (14 lb ft). 7. Remove the rubber cap or plug from the right brake line. Note: When installing the brake hose or brake line fittings, always finger-tighten the fitting before tightening to specification. 8. Install the right brake line to the brake hose and tighten the fitting to 19 Nm (14 lb ft). 9. Fill the master cylinder reservoir, if needed. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 10. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). 11. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6510 Brake Hose/Line: Service and Repair Power Brake Booster Vacuum Check Valve and Hose Replacement Power Brake Booster Vacuum Check Valve and Hose Replacement (5.3L) Removal Procedure 1. Apply and release the brake pedal several times to deplete the vacuum brake booster vacuum reserve. 2. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 3. Disconnect the vacuum brake booster check valve (1) from the power vacuum brake booster. Release the vacuum hose clamp and remove the check valve from the hose, if necessary. 4. Release the clamp and disconnect the vacuum hose (1) from the intake manifold vacuum port. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 6511 Installation Procedure 1. Connect the vacuum hose (1) from the intake manifold vacuum port. Position the clamp to secure the hose to the intake manifold. 2. Install the check valve to the vacuum hose, if removed. Position the clamp to secure the hose to the check valve. 3. Connect the vacuum brake booster check valve (1) to the power vacuum brake booster. A small amount of denatured alcohol may be used as a lubricant to ease assembly, if necessary. 4. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel Brake Proportioning/Combination Valve: Customer Interest Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6520 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6521 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel Brake Proportioning/Combination Valve: All Technical Service Bulletins Brakes - Brake Pedal Spongy/Increased Pedal Travel TECHNICAL Bulletin No.: 09-05-25-003 Date: September 21, 2009 Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System) Models: 2009 Chevrolet Cobalt 2009 Chevrolet Colorado 2009 Chevrolet Equinox 2009 Chevrolet HHR 2009 GMC Canyon 2009 Pontiac G5 2009 Pontiac Torrent 2009 Pontiac Solstice 2009 Saturn SKY 2009 Saturn VUE Equipped With RPO JL4 Only Condition Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop. Cause This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV). Correction 1. Perform the Diagnostic System Check - Vehicle. ‹› If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If DTCs are not present, proceed with this bulletin. 2. Inspect the master cylinder for the proper brake fluid level. 3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI. 4. Verify the customer concern by road testing the vehicle. Note Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers. 5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units. List of Affected Units Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6527 - 2428 - 2438 - 2448 - 2458 - 2468 - 2478 - 2488 - 2498 ‹› If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin. ‹› If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI. 6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI. 7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container. 8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI. 9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI. 10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 09-05-25-003 > Sep > 09 > Brakes - Brake Pedal Spongy/Increased Pedal Travel > Page 6528 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition switch to the OFF position. 2. Disconnect the electronic brake control module (EBCM) electrical connector. 3. Clean the area around the brake pipe fittings and the EBCM and the brake pressure modulator valve (BPMV) mating surfaces of any accumulated dirt and debris. 4. Disconnect the RF brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6532 5. Disconnect the RR brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 6. Disconnect the LR brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6533 7. Disconnect the LF brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 8. Disconnect the master cylinder primary brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6534 9. Disconnect the master cylinder secondary brake pipe fitting (1) from the EBCM/BPMV assembly. Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 10. Remove the EBCM/BPMV assembly bracket nuts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6535 11. Remove the EBCM/BPMV assembly (1). 12. If necessary, remove the BPMV bracket bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6536 13. If necessary, remove the bracket (1) from the BPMV. 14. Remove the EBCM. Refer to Electronic Brake Control Module Replacement (See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Service and Repair). Installation Procedure 1. Install the EBCM. Refer to Electronic Brake Control Module Replacement (See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Service and Repair). 2. If removed, install the bracket (1) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6537 3. If removed, install the BPMV bracket bolts (1) and tighten to 11 Nm (97 lb in). 4. Install the EBCM/BPMV assembly (1) to the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6538 5. Install the EBCM/BPMV assembly bracket nuts (1) and tighten to 9 Nm (80 lb in). Connect the master cylinder secondary brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 32 Nm (24 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6539 Connect the master cylinder primary brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 32 Nm (24 lb ft). Connect the LF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6540 Connect the LR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). 6. Connect the RR brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6541 7. Connect the RF brake pipe fitting (1) to the EBCM/BPMV assembly and tighten to 17 Nm (13 lb ft). 8. Connect the EBCM electrical connector. 9. Perform the Antilock Brake System Automated Bleed Procedure (See: Brake Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Master Cylinder Reservoir Filling). 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6546 brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6547 Brake Master Cylinder: Removal and Replacement Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Using a suitable tool, remove and properly discard the brake fluid from the master cylinder reservoir. 2. Clean the master cylinder reservoir and master cylinder assembly with denatured alcohol to remove any accumulated dirt and debris and allow to dry. 3. Disconnect the brake fluid level indicator switch electrical connector. 4. Carefully spread the 4 master cylinder reservoir locking legs and lift the master cylinder reservoir (1) upward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6548 5. Remove the master cylinder reservoir seals (1). Installation Procedure 1. Lightly lubricate the master cylinder reservoir seals with the recommended brake fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). 2. Install the master cylinder reservoir seals (1). 3. Install the master cylinder reservoir (1) to the master cylinder. Ensure the 4 locking legs of the master cylinder reservoir fully engage the master cylinder. 4. Connect the brake fluid level indicator switch electrical connector. 5. Fill the master cylinder reservoir with the recommended brake fluid. Refer to Master Cylinder Reservoir Filling (See: Procedures/Master Cylinder Reservoir Filling). Master Cylinder Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6549 Master Cylinder Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve. 2. Using a suitable tool, remove and properly discard the brake fluid from the master cylinder reservoir. 3. Clean the master cylinder assembly with denatured alcohol to remove any accumulated dirt and debris and allow to dry. 4. Disconnect the brake fluid level indicator switch electrical connector. 5. Disconnect the master cylinder secondary brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. 6. Disconnect the master cylinder primary brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6550 7. Remove the master cylinder nuts (1). 8. Remove the master cylinder (1) and O-ring seal (2) from the power vacuum brake booster. Inspect the O-ring seal for damage and replace, if necessary. Installation Procedure 1. If installing a new master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (See: Procedures/Master Cylinder Bench Bleeding). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6551 2. Install the master cylinder (1) and O-ring seal (2) to the power vacuum brake booster. Ensure the O-ring seal is properly positioned in the groove in the master cylinder body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the master cylinder nuts (1) and tighten to 30 Nm (22 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6552 4. Connect the master cylinder primary brake pipe fitting (1) and tighten to 17 Nm (13 lb ft). 5. Connect the master cylinder secondary brake pipe fitting (1) and tighten to 17 Nm (13 lb ft). 6. Connect the brake fluid level indicator switch electrical connector. 7. Fill the master cylinder reservoir with the recommended brake fluid. Refer to Master Cylinder Reservoir Filling (See: Procedures/Master Cylinder Reservoir Filling). 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove the rear brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 2. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the brake pipe fitting and plug the wheel cylinder inlet port to prevent brake fluid loss and contamination. 3. Remove the wheel cylinder bolts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Page 6556 4. Remove the wheel cylinder (1). Installation Procedure 1. Install the wheel cylinder (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Page 6557 2. Install the wheel cylinder bolts (1) and tighten to 18 Nm (13 lb ft). 3. Connect the brake pipe fitting (1) to the wheel cylinder and tighten to 19 Nm (14 lb ft). 4. Install the rear brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 5. Bleed the wheel cylinder. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures Parking Brake Cable: Procedures Parking Brake Cable Equalizer Replacement Replacement Procedure 1. Release the park brake. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake adjusting nut. 4. Remove the front park brake cable from the equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6563 5. Remove the right rear park brake cable from the equalizer. 6. Remove the left rear park brake cable from the equalizer. 7. Remove the equalizer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6564 1. Install the left rear park brake cable in the equalizer. 2. Install the right rear park brake cable in the equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6565 3. Install the front park brake cable in the equalizer. 4. Install the park brake cable adjusting nut. 5. Adjust the park brake cable. Refer to Parking Brake Adjustment (See: Adjustments). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6566 Parking Brake Cable: Removal and Replacement Parking Brake Release Cable Replacement Parking Brake Release Cable Replacement Removal Procedure 1. Release the park brake pedal. 2. Remove the knee bolster panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 3. Press the locking tabs for the release handle. 4. Remove the release handle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6567 5. Press the locking tabs for the release cable at the lower dash panel. 6. Remove the release cable from the lower dash panel. 7. Remove the release cable from the park brake pedal mounting bracket. 8. Remove the release cable from the release lever. 9. Remove the release cable. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6568 Important: Ensure that the release cable is properly seated in the release lever. 1. Install the release cable to the release lever. Important: When installing the park brake release handle or cable, ensure that the locking tabs are properly seated. A snap or clip should be heard or felt if installed properly. 2. Attach the release cable in the park brake pedal mounting bracket. 3. Install the release cable to the knee bolster panel. 4. Install the knee bolster panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6569 5. Install the park brake release handle to the release cable. Parking Brake Rear Cable Replacement - Left Side Parking Brake Rear Cable Replacement - Left Side Special Tools J 37043 Parking Brake Cable Release Tool Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Release the park brake. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6570 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake cable adjusting nut. 4. Remove the front park brake cable from the equalizer. 5. Remove the left rear park brake cable from the equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6571 6. On long wheel base vehicles, remove the park brake cable at the left frame rail. 7. Remove the retaining bolt from the left rear park brake cable. 8. On short wheel base vehicles, remove the park brake cable from the left frame rail. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6572 9. Remove the retainer for the park brake cables at the left frame rail. 10. Remove the park brake cable retaining nut at the left rear leaf spring. 11. Remove the left rear park brake cable retaining bracket. 12. Remove the rear brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6573 13. Using the J 37043 (1), remove the park brake cable from the backing plate. 14. Remove the park brake cable from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6574 1. Install the park brake cable into the backing plate. 2. Install the rear brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 3. Install the park brake cable to the retaining bracket at the rear leaf spring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the retaining nut and tighten to 9 Nm (80 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6575 5. Install the park brake cable to the left rear frame rail. 6. Install the retaining bolts and tighten to 9 Nm (80 lb in). 7. On short wheel base vehicles, install the park brake cable in the retaining bracket. 8. Install the retaining bolt for the park brake cable and tighten to 9 Nm (80 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6576 9. On long wheel base vehicles, install the park brake cable in the retaining bracket. 10. Install the left rear park brake cable to the park brake equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6577 11. Install the front park brake cable in the equalizer. 12. Install the adjuster nut. 13. Adjust the park brake. Refer to Parking Brake Adjustment (See: Adjustments). 14. Lower the vehicle. Parking Brake Rear Cable Replacement - Right Side Parking Brake Rear Cable Replacement - Right Side Special Tools J 37043 Parking Brake Cable Release Tool Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6578 Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Release the park brake, if applied. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the adjusting nut for the park brake. 4. Remove the front park brake cable from the equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6579 5. Remove the right park brake cable from the equalizer. 6. On short wheel base vehicles, remove the right park brake cable from the retainer on the left frame rail. 7. Remove the retaining bolt for the right park brake cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6580 8. On long wheel base vehicles, remove the right park brake cable from the retainer on the left frame rail. 9. Remove the retaining bolt for the park brake cable. 10. Remove the park brake cable from the crossmember. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6581 11. Remove the right park brake cable retaining bolts from the right rear frame rail. 12. Remove the retaining nut at the right rear spring bracket. 13. Remove the park brake cable from the retaining bracket. 14. Remove the rear brakes shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6582 15. Using the J 37043 (1), remove the park brake cable from the backing plate. 16. Remove the park brake cable from the backing plate. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6583 1. Install the park cable in the backing plate. 2. Install the rear brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 3. Install the park brake cable to the rear spring retaining bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the retaining nut to the park brake cable and tighten to 9 Nm (80 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6584 5. Install the park brake cable retaining bolts to the right rear frame rail and tighten to 9 Nm (80 lb in). 6. Install the park brake cable to the crossmember. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6585 7. On long wheel base vehicles, install the park brake cable to the left frame rail and tighten to 9 Nm (80 lb in). 8. Install the park brake cable retaining bolts and tighten to 9 Nm (80 lb in). 9. On short wheel base vehicles, install the park brake cable to the left frame rail. 10. Install the park brake cable retaining bolt and tighten to 9 Nm (80 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6586 11. Install the park brake cable to the equalizer. 12. Install the front park brake cable to the equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6587 13. Loosely install the adjuster nut. 14. Adjust the park brakes. Refer to Parking Brake Adjustment (See: Adjustments). 15. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Parking Brake Lever Pedal Assembly Replacement Removal Procedure 1. Release the park brake. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the wheel house inner liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 4. Remove the park brake cable adjusting nut. 5. Remove the front park brake cable from the equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 6591 6. Remove the retaining bolt for the front park brake cable. 7. Remove the knee bolster panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 8. Remove the clutch pedal assembly. Refer to Clutch Pedal Replacement (See: Transmission and Drivetrain/Clutch/Clutch Pedal Assembly/Service and Repair). 9. Remove the electrical connector from the brake switch. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 6592 10. Remove the park brake cable pedal mounting bolts. 11. Remove the front park brake cable weather seal. 12. Remove the park brake pedal assembly from the vehicle. 13. Remove the front park brake pedal and cable assembly from the vehicle noting routing for installation. Installation Procedure 1. Install the park brake pedal and cable assembly as previously routed. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the mounting bolts for the park brake pedal assembly and tighten to 20 Nm (15 lb ft). 3. Install the front park brake cable weather seal. 4. Install the clutch pedal assembly. Refer to Clutch Pedal Replacement (See: Transmission and Drivetrain/Clutch/Clutch Pedal Assembly/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 6593 5. Install the retaining bolt for the front park brake cable at the wheel well and tighten the bolt to 20 Nm (15 lb ft). 6. Install the front park brake cable to the equalizer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 6594 7. Install the park brake cable adjusting nut. Refer to Parking Brake Adjustment (See: Adjustments). 8. Install the wheel house liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 9. Install the knee bolster panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 10. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views Parking Brake Release Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6599 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6600 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6601 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6602 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6603 Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Below the I/P Components - 2 of 2 1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowl Side Inner Panel Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Page 6604 Parking Brake Release Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Page 6608 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in). 3. Install the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Page 6609 4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement Removal Procedure 1. Apply and release the brake pedal several times until the pedal becomes firm to deplete the brake booster vacuum reserve. 2. Disconnect the power vacuum brake booster vacuum hose and check valve (1). 3. Remove the master cylinder assembly. Refer to Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement). 4. Remove the knee bolster. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 5. Remove the brake booster pushrod retainer (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 6614 6. Remove the brake booster pushrod clevis pin (1). 7. Remove the power vacuum brake booster nuts (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 6615 8. Remove the power vacuum brake booster (1). 9. Remove the power vacuum brake booster gasket (2). Inspect the gasket for damage and replace, if necessary. Installation Procedure 1. Install the power vacuum brake booster (1) and gasket (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 6616 2. Install the power vacuum brake booster nuts (1) and tighten to 20 Nm (15 lb ft). 3. Install the brake booster pushrod clevis pin (1) to the pushrod and the brake pedal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 6617 4. Install the brake booster pushrod retainer (1). 5. Install the knee bolster. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 6. Install the master cylinder assembly. Refer to Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement). 7. Connect the power vacuum brake booster vacuum hose and check valve (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6623 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6624 Electronic Brake Control Module: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6625 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6626 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6627 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6628 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6629 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition switch to the OFF position. 2. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair). 3. Remove the electronic brake control module (EBCM) bolts (1). Discard the bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6630 4. Carefully separate the EBCM (1) from the BPMV. 5. Remove the 12 EBCM to BPMV seals (2). Installation Procedure 1. Carefully install the EBCM (1) and the 12 seals (2) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Do not reuse the EBCM bolts. Install new bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6631 2. Install new EBCM bolts (1) and tighten to 2 Nm (18 lb in). 3. Install the EBCM/BPMV assembly to the vehicle. Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair Acceleration/Deceleration Sensor: Service and Repair Longitudinal Accelerometer Replacement Removal Procedure 1. Remove the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). 2. Access the sensor through service slit provided in the carpet. 3. Disconnect the longitudinal accelerometer electrical connector. 4. Remove the nuts (1) from the longitudinal accelerometer. 5. Remove the longitudinal accelerometer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 6636 1. Install the longitudinal accelerometer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the longitudinal accelerometer nuts (1) and tighten to 9 Nm (80 lb in). 3. Connect the longitudinal accelerometer electrical connector. 4. Install the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6641 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6642 Brake Fluid Level Sensor/Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6643 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6644 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6645 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6646 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Removal Procedure 1. Remove the electrical connector from the sensor. 2. Using a pair of needle nose pliers bend on a 90 degree angle, release the retaining clip. 3. Remove the sensor from the master cylinder. Installation Procedure 1. Install the fluid sensor in the master cylinder. Make sure that the sensor is fully seated. 2. Install the electrical connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 6650 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 6651 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 6652 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 6653 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 6654 Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (2WD) (JL4) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views Parking Brake Release Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6659 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6660 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6661 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6662 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Harness Routing Views > Page 6663 Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Below the I/P Components - 2 of 2 1 - Park Brake Switch Connector 2 - Body Harness 3 - Park Brake Switch 4 - Park Brake Lever 5 Cowl Side Inner Panel Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 6664 Parking Brake Release Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Page 6668 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in). 3. Install the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Page 6669 4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams Traction Control Switch: Diagrams Component Connector End Views Traction Control Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 6673 Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Wheel Speed Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6678 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6679 Wheel Speed Sensor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6680 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6681 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6682 Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Front Wheel Knuckle Components 1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Left Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 6683 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front Wheel Speed Sensor (WSS) - Right Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 6684 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Within the engine compartment, disconnect the wheel speed sensor electrical connector (1). 2. Release the wheel speed sensor harness connector from the wheelhouse. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 5. Release the wheel speed sensor harness clips (1) from the suspension upper control arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6687 6. Release the wheel speed sensor harness grommet (1) from the mounting bracket. 7. Remove the wheel speed sensor harness bracket bolt (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6688 8. Thoroughly clean the wheel speed sensor mounting area of the steering knuckle of any dirt and debris. 9. Remove the wheel speed sensor bolt (1). Note: Do not pry or lever against the wheel speed sensor to remove. 10. Carefully remove the wheel speed sensor from the suspension knuckle by pulling straight upward. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6689 1. Install the wheel speed sensor to the suspension knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 8 Nm (71 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6690 3. Install the wheel speed sensor harness bracket bolt (1) and tighten to 9 Nm (80 lb in). 4. Install the wheel speed sensor harness grommet (1) to the mounting bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6691 5. Install the wheel speed sensor harness clips (1) to the suspension upper control arm. 6. Install the wheel speed sensor harness connector to the wheelhouse. 7. Connect the wheel speed sensor electrical connector (1). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6692 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the wheel speed sensor bolts (1). 3. Remove the wheel speed sensor (1) from the drum brake backing plate by carefully pulling straight outward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6693 4. Release the wheel speed sensor harness retainers (1) on the rear park brake cable. Release the harness from the retainers. 5. Disconnect the wheel speed sensor electrical connector (1). 6. Release the electrical connector and harness retainer (2) from the frame. 7. Remove the wheel speed sensor assembly. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6694 1. Position the wheel speed sensor assembly to the vehicle. 2. Connect the wheel speed sensor electrical connector (1). 3. Install the electrical connector and harness retainer (2) to the frame. 4. Position the wheel speed sensor harness to the retainers (1) on the rear park brake cable. 5. Fasten the wheel speed sensor harness retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6695 6. Install the wheel speed sensor (1) to the drum brake backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the wheel speed sensor bolts (1) and tighten to 17 Nm (13 lb ft). 8. Lower the vehicle. 9. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6699 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6700 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6701 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6702 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6703 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (2WD) (JL4) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6704 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 6710 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 6711 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 6712 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 6713 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding This vehicle has two different types of ignition lock cylinders based on what type of steering column the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder designs. Ignition Lock Cylinder The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side. Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into the case assembly (5). 1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3. The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install this tumbler in the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4 tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8. Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct key into the lock cylinder. All tumblers (1) should be flush with the housing of the lock cylinder. 9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM Super Lube GM P/N 12346241 or equivalent light lithium grease. 10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front face of the rotor. If the slide piece is installed incorrectly, the key cannot insert into the rotor due to no access to the ramp. 11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock cylinder housing. Ensure that the actuator lever is inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should pivot on the pin against spring tension. 12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side with the security plug (3) faces to the left of the key head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6719 13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the center of the lock cylinder housing (1) and hold it. Insert the coded lock cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the housing. 15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward slightly. The key should be able to be removed and the lock cylinder should remain in the housing. 16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the lock cylinder housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6720 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4. Remove the ignition lock cylinder case. Installation Procedure 1. Install the ignition lock cylinder case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition switch, a passlock relearn will be needed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining pin down. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6721 5. Pull the ignition lock cylinder away from the steering column. Installation Procedure 1. Install the ignition lock cylinder by performing the following procedure: 1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until the retaining pin locks it in place. 2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Battery Control Module > Component Information > Diagrams Battery Control Module: Diagrams Component Connector End Views Generator Battery Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement Charging System Control Module: Service and Repair Generator Battery Control Module Replacement Generator Battery Control Module Replacement (V8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 6730 Charging System Control Module: Service and Repair Generator Battery Control Module Replacement (4 and 5 Cylinder) Generator Battery Control Module Replacement (4 and 5 Cylinder) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair Negative: Service and Repair Battery Negative Cable Replacement (LH8) (5.3L) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Service and Repair). 2. Remove the negative battery cable clip (2) from the lower half of the battery box. 3. Remove the negative battery cable clip (3) from the battery tray. 4. Remove the negative battery cable integral bolt (4) from the battery tray. 5. Disconnect the engine wiring harness electrical connector (6) from the battery current sensor (5). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Page 6739 6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 7. Remove the negative battery cable ground bolt (4). 8. Remove the negative battery cable clip (2) from the engine wiring harness bracket. 9. Lower the vehicle. 10. Remove the negative battery cable clip (1) from the engine wiring harness bracket. 11. Remove the negative battery cable (3) from the vehicle. Installation Procedure Note: * The negative battery cable must not be connected to the battery prior to the installation of the engine harness ground terminal to the engine block. * The negative battery cable must not be connected to the battery prior to the installation of the instrument panel harness and the engine harness to the powertrain control module. 1. Install the negative battery cable (3) to the vehicle. 2. Install the negative battery cable clip (1) to the engine wiring harness bracket. 3. Raise and suitably support the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Page 6740 4. Install the negative battery cable clip (2) to the engine wiring harness bracket. 5. Ensure that the engine wiring harness ground terminal (5) is position against the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Position the negative battery cable ground terminal over the engine wiring harness ground and install the negative battery cable ground bolt (4). Tighten the bolt to 25 Nm (18 lb ft). 7. Lower the vehicle. 8. Connect the engine wiring harness electrical connector (6) to the battery current sensor (5). 9. Install the negative battery cable integral bolt (4) to the battery tray. Tighten the bolt to 40 Nm (29.5 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Page 6741 10. Install the negative battery cable clip (3) to the battery tray. 11. Install the negative battery cable clip (2) to the lower half of the battery box. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Control Module > Component Information > Diagrams Battery Control Module: Diagrams Component Connector End Views Generator Battery Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement Battery Tray: Service and Repair Battery Tray Replacement Battery Tray Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Body and Frame/Service Precautions/Approved Equipment for Collision Repair Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Cable/Service and Repair). 3. Remove all related panels and components. 4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body (). 5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement > Page 6749 Note: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of welds for installation of the battery tray. 7. Remove the damaged battery tray. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement > Page 6750 Note: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (11/2 in) apart. 1. Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original battery tray. 2. Prepare all mating surfaces as necessary. 3. Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair (). 4. Position the battery tray. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement > Page 6751 5. Plug the weld accordingly. 6. Clean and prepare all welded surfaces. 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 9. Install all related panels and components. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Cable/Service and Repair). 11. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement > Page 6752 Battery Tray: Service and Repair Battery Box Replacement Battery Box Replacement Removal Procedure 1. Remove the battery. Refer to Battery Replacement (LLV/LLR) (See: Service and Repair)Battery Replacement (LH8) (See: Service and Repair). 2. Disconnect the following from the lower battery box (2): * The battery cables harness retainer (3) * The engine wiring harness retainer 3. Lift the lower battery box (2) upward from the battery tray (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement > Page 6753 Installation Procedure 1. Install the lower battery box (2) to the retainer stud (1) and battery tray (3). 2. Connect the following to the lower battery box (2): * The battery cables harness retainer (3) * The engine wiring harness retainer 3. Install the battery. Refer to Battery Replacement (LLV/LLR) (See: Service and Repair)Battery Replacement (LH8) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications Generator Usage Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6758 Alternator: Diagrams Component Connector End Views Generator X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement Generator Bracket Replacement (LH8) (5.3L) Removal Procedure 1. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Generator Replacement)Generator Replacement (LH8) (See: Generator Replacement). 2. Remove the power steering pump. Refer to Power Steering Pump Replacement (LLV, LLR) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (LH8) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 3. Remove the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Idler Pulley/Service and Repair). 4. Remove the engine wiring harness bracket bolt (4). 5. Reposition the engine wiring harness bracket out of the way. 6. Remove the generator bracket bolts. 7. Remove the generator bracket. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 6761 1. Install the generator bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bracket bolts and tighten to 50 Nm (37 lb ft). 3. Position the engine wiring harness bracket to the generator bracket. 4. Install the engine wiring harness bracket bolt (4) and tighten to 40 Nm (29.5 lb ft). 5. Install the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Idler Pulley/Service and Repair). 6. Install the power steering pump. Refer to Power Steering Pump Replacement (LLV, LLR) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (LH8) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Generator Replacement)Generator Replacement (LH8) (See: Generator Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 6762 Alternator: Service and Repair Generator Replacement Generator Replacement (LH8) (5.3L) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Service and Repair). 2. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 3. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 4. Disconnect the engine wiring harness electrical connector (1) from the generator. 5. Reposition the engine wiring harness/positive battery cable boot (5). 6. Remove the engine wiring harness/positive battery cable nut from the generator. 7. Remove the engine wiring harness/positive battery cable (2) from the generator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 6763 8. Remove the generator bolts. 9. Remove the generator. Installation Procedure 1. Install the generator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bolts. Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 6764 3. Install the engine wiring harness/positive battery cable (2) to the generator. 4. Install the engine wiring harness/positive battery cable nut to the generator. Tighten the nut to 9 Nm (80 lb in). 5. Position the engine wiring harness/positive battery cable boot (5). 6. Connect the engine wiring harness electrical connector (1) to the generator. 7. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 8. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Charging System Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement Charging System Control Module: Service and Repair Generator Battery Control Module Replacement Generator Battery Control Module Replacement (V8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Charging System Control Module > Component Information > Service and Repair > Generator Battery Control Module Replacement > Page 6769 Charging System Control Module: Service and Repair Generator Battery Control Module Replacement (4 and 5 Cylinder) Generator Battery Control Module Replacement (4 and 5 Cylinder) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Clutch Switch: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 6774 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 6775 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 6776 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 6777 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding This vehicle has two different types of ignition lock cylinders based on what type of steering column the vehicle is equipped with. The electric power steering (EPS) option, usually found on 4 cylinder models, and the non EPS, usually found on 6 cylinder models, use different ignition lock cylinder designs. Ignition Lock Cylinder The ignition lock cylinder uses all 10 key cut positions, 1-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 5 tumblers on each side. Important: The ignition lock cylinder tumblers (1) are not self retaining and must be held in place if the key is not fully inserted in the lock cylinder (2), or until the lock cylinder (2) is assembled into the case assembly (5). 1. Hold the uncoded cylinder assembly (2) positioned so the side with the security plug (3) faces to the left of the key head. 2. Insert one tumbler spring (7) into each of the 4 tumbler spring holes. 3. The first tumbler (1) to be loaded will be key cut position 1, the first number in the key code. Install this tumbler in the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 4. Advancing one tumbler slot at a time, install tumblers 3, 5, and 7 sequentially on the same side as tumbler 1. 5. Turn the lock cylinder over and insert one tumbler spring (7) into each of the 4 tumbler spring holes on the opposite side of the lock cylinder. 6. Insert tumbler 2 into the tumbler slot closest to the head of the lock cylinder (2), the end where the key is inserted. 7. Advancing one tumbler slot at a time, install tumblers 4, 6, and 8 sequentially on the same side as tumbler 2. 8. Check for correct tumbler loading by holding the tumblers (1) in position and inserting the correct key into the lock cylinder. All tumblers (1) should be flush with the housing of the lock cylinder. 9. Lightly lubricate the tumblers and small detent recessed areas the tumblers are in with GM Super Lube GM P/N 12346241 or equivalent light lithium grease. 10. Take the slide piece and insert into the rotor. Ensure "Front of Sliding Piece" is facing the front face of the rotor. If the slide piece is installed incorrectly, the key cannot insert into the rotor due to no access to the ramp. 11. Install the pivot pin into the actuator lever and install the actuator lever into the ignition lock cylinder housing. Ensure that the actuator lever is inside of the lock cylinder housing at the end close to key insertion opening. Actuator lever should pivot on the pin against spring tension. 12. Insert the key into the coded lock cylinder (2) and hold the lock cylinder positioned so the side with the security plug (3) faces to the left of the key head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6783 13. Hold the ignition lock housing positioned so the security plug actuator lever (3) also faces to the right of the key head. 14. Push the exposed end of the security plug actuator lever (3) toward the center of the lock cylinder housing (1) and hold it. Insert the coded lock cylinder (2) with the key in it into the ignition lock cylinder housing (1) until the cap is flush with the housing. 15. Rotate the keyed lock cylinder counterclockwise slightly until it stops and detents outward slightly. The key should be able to be removed and the lock cylinder should remain in the housing. 16. Install the retaining clip (1) onto the coded lock cylinder where it comes out of the back of the lock cylinder housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6784 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure 1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 2. Remove the multifunction turn signal switch housing. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 3. Remove the shear bolt from the ignition lock cylinder case using a hammer and chisel. 4. Remove the ignition lock cylinder case. Installation Procedure 1. Install the ignition lock cylinder case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition lock cylinder case bolt and tighten it until the head shears off. 3. Install the multifunction turn signal switch. Refer to Multifunction Turn Signal Switch Housing Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Multifunction Turn Signal Switch Housing Replacement). 4. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement (See: Ignition Lock Cylinder Replacement). 5. The passlock sensor is part of the ignition switch. If replacing the ignition switch, a passlock relearn will be needed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure 1. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 2. Turn the ignition lock cylinder to the accessory position. 3. Insert the 90 degree tip of a pick type tool into the ignition lock cylinder access hole. 4. Push and hold the ignition lock cylinder retaining pin down. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 6785 5. Pull the ignition lock cylinder away from the steering column. Installation Procedure 1. Install the ignition lock cylinder by performing the following procedure: 1. Turn the ignition lock cylinder to the accessory position. 2. Push the ignition lock cylinder in until the retaining pin locks it in place. 2. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 6790 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 6791 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 6792 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Starter Motor: Locations Powertrain Component Views Engine - Right Side (LH8) 1 - Crankshaft Position (CKP) Sensor 2 - Ignition Coil 8 3 - Ignition Coil 6 4 - Ignition Coil 4 5 Manifold Absolute Pressure (MAP) Sensor 6 - Ignition Coil 2 7 - A/C Compressor Clutch 8 - Knock Sensor (KS) 2 9 - Starter Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6796 Starter Motor: Diagrams Component Connector End Views Starter X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6797 Starter Motor: Service and Repair Starter Motor Replacement (LH8) (5.3L) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Service and Repair). 2. Remove the right front tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the engine wiring harness/positive battery cable terminal nut (4) and cable terminal (5) from the starter. 4. Disconnect the engine wiring harness electrical connector (2) from the starter motor. 5. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 6. Remove the transmission cover bolt (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6798 7. Remove the starter motor bolts. 8. Unsnap the transmission cover from the starter. 9. Remove the starter heat shield, if required. 10. Remove the starter. Installation Procedure 1. Install the starter heat shield, if required. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6799 2. Install the transmission cover to the starter. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Position the starter and install the starter motor bolts. Tighten the bolts to 50 Nm (37 lb ft). 4. Install the transmission cover bolt (1). Tighten the bolt to 12 Nm (106 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6800 5. Connect the engine wiring harness electrical connector (2) to the starter motor. 6. Install the engine wiring harness/positive battery cable terminal (5) to the starter and install the nut (4). Tighten the nut to 9 Nm (80 lb in). 7. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 8. Install the right front tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6834 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6838 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6853 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6854 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6855 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6856 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6857 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6858 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6859 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6860 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6861 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6862 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6863 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6864 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6865 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6866 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6867 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6868 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6869 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6870 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6871 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6872 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6873 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6874 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6924 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6925 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6926 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 (KC5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6985 Auxiliary Power Outlet: Service and Repair 115-Volt AC Instrument Panel Accessory Power Receptacle Replacement Tools Required J 42059 Cigarette Lighter Socket Remover Removal Procedure 1. Remove the 12 volt power supply or cigar lighter fuse. 2. Remove the socket by placing one side of the "T" portion of the tool J 42059 into the socket and into the square window tab. 3. Position the opposite "T" portion of the tool into the opposing square window tab. 4. Pull the socket straight out of the retaining ring. 5. Remove the tool from the socket. 6. Disconnect the electrical connector from the socket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6986 7. Using your finger, remove the socket retaining ring by pulling the retaining ring out of the mounting hole. Installation Procedure 1. Position the retaining ring to the mounting hole. 2. Index the key to the retaining ring to the slot in the mounting hole. 3. Install the retaining ring by pressing the retaining ring into the mounting hole until fully seated. 4. Connect the electrical connector to the socket. 5. Position the socket to the retaining ring. 6. Install the socket into the retaining ring by pressing in the socket until fully seated. 7. Install the 12 volt power supply or cigar lighter fuse. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6987 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-46-002D > Jul > 09 > Audio System Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-46-002D > Jul > 09 > Audio System Noise When Using OnStar(R) > Page 6996 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 7002 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7008 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7009 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7010 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7011 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7012 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7018 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7019 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7020 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7021 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 7022 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start Fuse: Customer Interest Electrical - Dead Battery/No Crank/No Start TECHNICAL Bulletin No.: 08-06-03-010 Date: September 30, 2008 Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC) Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System Message (Install 125 Amp Mega Fuse) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3 Condition Some customers may comment on the following conditions: ^ The battery runs down. ^ The engine will not crank. ^ The engine will not start. ^ The Instrument Panel Cluster charge indicator turns on. ^ The Driver Information Center displays a Service Charge System message. Cause This condition may be caused by an open Mega Fuse in the underhood electrical center. Correction Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 7031 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start TECHNICAL Bulletin No.: 08-06-03-010 Date: September 30, 2008 Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC) Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System Message (Install 125 Amp Mega Fuse) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3 Condition Some customers may comment on the following conditions: ^ The battery runs down. ^ The engine will not crank. ^ The engine will not start. ^ The Instrument Panel Cluster charge indicator turns on. ^ The Driver Information Center displays a Service Charge System message. Cause This condition may be caused by an open Mega Fuse in the underhood electrical center. Correction Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 7037 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block Fuse: Locations Engine Compartment Fuse Block ENGINE COMPARTMENT FUSE BLOCK The engine compartment fuse block is located on the driver side of the engine compartment. To remove the cover, push in on the tab on the end of the cover and lift. To reinstall the cover, line up the tab and push down on the cover until the tab clicks into place. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7040 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7041 The trailer brake relay is located on the bottom side of the battery harness. FUSES ................................................................................................................................................. ..................................................................... USAGE O2 SNSR .......................................................................................................................................... Oxygen Sensors, Air Injection Reactor (AIR) Relay A/C .............................................................................................................................................................. Air Conditioning Control Head, Power Seats A/C CMPRSR ............................................................... ...................................................................................................... Air Conditioning Compressor ABS .................................................................................................... Antilock Brake System (ABS), ABS Module, Four-Wheel Drive, Gravity Sensor ABS 1 .............................................................................. ................................................................................................................... ABS 1 (ABS Logic) ABS 2 .............................................................................................................................................................. ................................... ABS 2 (ABS Pump) AUX PWR 1 ..................................................................... ................................................................................................................... Accessory Power 1 AUX PWR 2 ................................................................................................................................................. ....................................... Accessory Power 2 BCK/UP ....................................................................... .............................................................................................................................. Back-up Lights BLWR .................................................................................................................................................. .............................................. Climate Control Fan CLSTR ................................................................. ................................................................................................................................................... Cluster CNSTR VENT ......................................................................................................................... ............................................. Fuel Canister Vent Solenoid CRUISE ............................................... Cruise Control Switch, Inside Rearview Mirror, Transfer Case Control Module, Brake Switch, Clutch Disable DR/LCK .................................................................................................................................. ....................................... Power Door Locks (If Equipped) DRL ......................................................... ................................................................................................................................... Daylight Running Lamps ERLS .......................................................................................... Mass Air Flow (MAF) Sensor, Can Purge Solenoid, Air Injector Reactor (AIR) Relay ETC ....................................... ...................................................................................................................................... Electronic Throttle Control (ETC) FOG/LAMP ...................................................................................................... ......................................................................... Fog Lamps (If Equipped) FRT PRK LAMP ....................................................................... Front Park/Turn Lamps, Driver and Passenger Side Power Window Switches Lighting FRT/AXLE ..................................................................................... .................................................................................................... Front Axle Actuator FSCM .............. .............................................................................................................................................................. ....... Fuel System Control Module BACKUP LAMP ............................................................................. ............................................................................................................ Backup Lamp HORN .............. .............................................................................................................................................................. ............................................ Horn HTD/SEAT ..................................................................................... .......................................................................................... Heated Seat (If Equipped) IGN ........................................................... Ignition, Clutch Starter Switch, Neutral Safety Back-Up Switch, Ignition Coils 1-5, Air Conditioning Relay INJ ......................................................................... ............................................................................................................................................... Injectors LT HDLP .............................................................................................................................................. .......................................... Driver Side Headlamp PCM B .................................................................. ......................................................................................................... Power Control Module (PCM) B PCMI .................................................................................................................................................... ............................. Power Control Module (PCM) PWR/SEAT ...................................................................................................................................................... Power Seat Circuit Breaker (If Equipped) PWR/WNDW ..................................................................... ............................................................................................... Power Windows (If Equipped) RDO .... .............................................................................................................................................................. ........................................................ Radio REAR PRK LAMP .............................................................................................. Rear Parking Lamp 1, Passenger Side Taillamp, License Plate Lamps REAR PRK LAMP2 ................ Driver Side Rear Taillamp, Passenger Side Airbag Indicator Lighting, Instrument Panel Dimming Power (2WD/4WD switch lighting) RT HDLP ............................................................................................................................................. ..................................... Passenger Side Headlamp RVC ................................................................... ...................................................................................................................... Regulated Voltage Control S/ROOF .................................................................................................................................. ........................................................ Sunroof (If Equipped) STOP ....................................................... ........................................................................................................................................................ Stop Lamps STRTR ............................................................................................................................ ............................................................... Starter Solenoid Relay TBC ................................................ ............................................................................................................................................... Truck Body Controller TCM ........................................................................................................................... ........................................................ Transmission Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7042 TCCM .................................................................................................................................................. .............................. Transfer Case Control Module TRAILER BRAKE ................................................ ....................................................................................................................................... Trailer Brake TRANS ................................................................................................................................................ .......................................... Transmission Solenoid TRN/HAZRD FRT ..................................................................................................................................... Turn/Hazard/Courtesy/Cargo Lamps/Mirrors TRN/HAZRD REAR ...................................................... ............................................................................................................ Rear Turn/Hazard Lights VSES ................................................................................................................................................... ................. Vehicle Stability Enhancement System WPR .................................................................... ..................................................................................................................................................... Wiper WSW ......................................................................................................................................... ...................................................... Wiper/Washer Switch RELAYS .............................................................................................................................................. .................................................................... USAGE A/C CMPRSR ...................................................................................................................................... ............................... Air Conditioning Compressor BEAM SEL ............................................................ ................................................................................................................................... Beam Selection DRL ..................................................................................................................................................... ....................................... Daylight Running Lamps FOG/LAMP .......................................................... ..................................................................................................................... Fog Lamps (If Equipped) BK UP LP ............................................................................................................................................ ...................................................... Back Up Lamp HDLP ................................................................... ............................................................................................................................................ Headlamps HORN ............................................................................................................................... ......................................................................................... Horn IGN 3 HVAC ................................................................................................. Ignition 3, Climate Control, Climate Control Head Fuse, Power Seat Fuse PRK/LAMP ............................................................................................................................................. Front Parking Lamp Fuse, Rear Parking Lamps PWR/TRN ................................................................................................................ Powertrain, Electronic Throttle Control Fuse, Oxygen Sensor Fuse RAP ................................................................................ Retained Accessory Power (Power Window Fuse, Wiper/Washer Switch Fuse), Sunroof Fuse RUN/CRNK ............ Run/Crank, Airbag System Fuse, Cruise Control Fuse, Ignition Fuse, Back-Up Lamps, ABS Fuse, Front Axle, PCM-1, Injectors Fuse, Transmission Fuse, ERLS STRTR ................................................................................................................................................. ................................... Starter Relay (PCM Relay) VSES ................................................................... ................................................................................................. Vehicle Stability Enhancement System WPR ....................................................................................................................................... ................................................................. Wipers (On/Off) WPR 2 ..................................................... .......................................................................................................................................... Wiper 2 (High/Low) MISCELLANEOUS .............................................................................................................................. ................................................................. USAGE A/C CLTCH .......................................................................................................................................... ....................... Diode -- Air Conditioning, Clutch MEGA FUSE ........................................................... ......................................................................................................................................... Mega Fuse WPR .................................................................................................................................................... ....................................................... Diode -- Wiper FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse A ................................................................................................................................................. .................................................. Trailer Park Lamp Fuse B ................................................................. .......................................................................................................... Communication Interface Module Fuse C .......................................................................................................... Supplemental Inflatable Restraint System, Sensing and Diagnostic Module Fuse D ................................................ ................................................................................................................................... Trailer Auxiliary Maxi-Fuse Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7043 Fuse: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7044 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7045 Fuse Block - Underhood - Top View Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7046 Fuse Block - Underhood - Bottom View Fuse Block - Underhood X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7047 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7048 Fuse Block - Underhood X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7049 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7050 Fuse Block - Underhood X4 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7051 Fuse Block - Underhood X5 Fuse Block - Underhood X6 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7052 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7053 Fuse Block - Underhood X7 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7054 Fuse Block - Underhood X9 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7055 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7056 Fuse: Application and ID Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7057 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7058 Fuse Block - Underhood - Top View Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7059 Fuse Block - Underhood - Bottom View Fuse Block - Underhood X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7060 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7061 Fuse Block - Underhood X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7062 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7063 Fuse Block - Underhood X4 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7064 Fuse Block - Underhood X5 Fuse Block - Underhood X6 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7065 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7066 Fuse Block - Underhood X7 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7067 Fuse Block - Underhood X9 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7068 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views Fuse Block: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7073 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Battery Cable Harness Routing 1 - G104 2 - Starter 3 - Generator X2 4 - Battery 5 - G100 6 - Battery Negative Terminal 7 - Fuse Block - Underhood 8 - Ring Terminal Battery 9 - Ring Terminal Generator 10 - Battery Positive Terminal 11 - Generator Body Harness Routing 1 of 3 (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7074 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7075 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7076 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7077 Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 1 - G104 2 - Starter 3 - Battery 4 - G100 5 - Fuse Block - Underhood 6 - Battery Positive Terminal 7 - Generator Left and Right Sides of Engine Compartment Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7078 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7097 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7098 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7099 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7101 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7151 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7152 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7153 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7154 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7187 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7206 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7207 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7208 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7209 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7210 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7211 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 7252 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Service and Repair). 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 4. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Installation Procedure 1. Align the wiring harnesses and install the fuse relay center (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 7253 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuse relay center bolts. Tighten the relay center bolts to 6 Nm (53 lb in). 3. Install the junction block cover (2). Press downward to engage the tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7258 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7259 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7260 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7261 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7262 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7263 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7272 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7278 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 Multiple Junction Connector: Diagrams X100 - X199 X103 Inline Harness Connector End Views X103 Forward Lamp Harness to the Body Harness X104 Inline Harness Connector End Views X104 Forward Lamp Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7281 X106 Inline Harness Connector End Views X106 Body Harness to the Chassis harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7282 X102 Inline Harness Connector End Views X102 Body Harness to the Chassis Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7283 X107 Inline Harness Connector End Views X107 Forward Lamp Harness to Right Front Turn Signal Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7284 X108 Inline Harness Connector End Views X108 Forward Lamp Harness to Left Front Turn Signal Harness X109 Inline Harness Connector End Views X109 Engine Harness to Battery Harness (K18) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7285 X110 Inline Harness Connector End Views X110 Chassis Harness to Engine Harness (UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7286 X125 Inline Harness Connector End Views X125 Engine Harness to the Body Harness X126 Inline Harness Connector End Views X126 Chassis Harness to the Engine Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7287 X175 Inline Harness Connector End Views X175 Engine Harness to Transmission Harness (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7288 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7289 Multiple Junction Connector: Diagrams X200 - X299 X200 Inline Harness Connector End Views X200 I/P Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7290 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7291 X201 Inline Harness Connector End Views X201 I/P Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7292 X202 Inline Harness Connector End Views X202 Driver Door Harness to the Body Harness (AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7293 X203 Inline Harness Connector End Views X203 I/P Harness to the HVAC Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7294 X204 Inline Harness Connector End Views X204 Steering Column Harness to the I/P Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7295 X209 Inline Harness Connector End Views X209 Body Harness to the Driver Door Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7296 X211 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7297 Inline Harness Connector End Views X211 Passenger Door Harness to the Body Harness (AU3) X208 Inline Harness Connector End Views X208 I/P Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7298 X210 Inline Harness Connector End Views X210 Body Harness to the Passenger Door Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7299 X275 Inline Harness Connector End Views X275 SIR Coil Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7300 X276 Inline Harness Connector End Views X276 Body Harness to the Steering Column Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7301 Multiple Junction Connector: Diagrams X300 - X399 X307 Inline Harness Connector End Views X307 Body Harness to the Driver Seat Harness (AG1) X310 Inline Harness Connector End Views X310 Dome Lamp Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7302 X311 Inline Harness Connector End Views X311 Body Harness to the Right Rear Passenger Door Harness (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7303 X312 Inline Harness Connector End Views X312 Body Harness to the Left Rear Passenger Door Harness (Extended Cab) X313 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7304 Inline Harness Connector End Views X313 Body Harness to the Passenger Seat Harness X316 Inline Harness Connector End Views X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7305 X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab without A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7306 X316 Body Harness to the Left Rear Passenger Door Harness (Extended Cab) X317 Inline Harness Connector End Views X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7307 X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab without A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7308 X317 Body Harness to the Right Rear Passenger Door Harness (Extended Cab) X318 Inline Harness Connector End Views X318 Heat Element to Passenger Seat Harness (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7309 X319 Inline Harness Connector End Views X319 Heat Element to Driver Seat Harness (AG1) X320 Inline Harness Connector End Views X320 Body Harness to Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7310 X314 Inline Harness Connector End Views X314 Body Harness to the Driver Seat Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7311 X315 Inline Harness Connector End Views X315 Body Harness to the Passenger Seat Harness (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7312 Multiple Junction Connector: Diagrams X400 - X499 X400 Inline Harness Connector End Views X400 Chassis Harness to the License Lamp Harness X403 Inline Harness Connector End Views X403 Left Rear Lamp Assembly to the Trailer Accessory Harness (Trailer Accessory) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7313 X404 Inline Harness Connector End Views X404 (UY7) Chassis Harness to License Lamp Harness X401 Inline Harness Connector End Views X401 Left Rear Lamp Assembly to the Chassis Harness (- UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7314 X401 Trailer Accessory Harness to the Chassis Harness (UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7315 X402 Inline Harness Connector End Views X402 Right Rear Lamp Assembly to the Chassis Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7316 X405 Inline Harness Connector End Views X405 (UY7) Trailer Jumper Harness to License Lamp Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7321 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7322 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7331 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7332 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7341 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7342 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7343 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7348 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7354 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7355 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7356 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7361 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7362 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7363 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7364 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7365 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7366 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7371 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7377 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7378 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7379 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7380 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7381 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7382 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7419 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7420 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7421 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7425 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7430 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7431 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7432 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7433 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7434 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7438 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7439 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7440 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7471 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7472 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7483 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7484 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7485 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7486 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7487 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7488 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7489 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7490 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7491 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7492 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7493 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7494 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7495 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7496 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7497 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7498 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7499 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7500 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7501 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7502 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7503 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7504 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7505 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7506 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7507 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7508 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7509 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7510 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7534 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7535 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7536 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7537 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7538 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7539 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7540 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7541 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7542 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7543 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7544 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7545 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7546 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7547 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7548 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7549 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7550 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7551 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7552 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7553 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7554 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7555 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7556 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7561 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7562 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 (KC5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7563 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 7564 Auxiliary Power Outlet: Service and Repair 115-Volt AC Instrument Panel Accessory Power Receptacle Replacement Tools Required J 42059 Cigarette Lighter Socket Remover Removal Procedure 1. Remove the 12 volt power supply or cigar lighter fuse. 2. Remove the socket by placing one side of the "T" portion of the tool J 42059 into the socket and into the square window tab. 3. Position the opposite "T" portion of the tool into the opposing square window tab. 4. Pull the socket straight out of the retaining ring. 5. Remove the tool from the socket. 6. Disconnect the electrical connector from the socket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 7565 7. Using your finger, remove the socket retaining ring by pulling the retaining ring out of the mounting hole. Installation Procedure 1. Position the retaining ring to the mounting hole. 2. Index the key to the retaining ring to the slot in the mounting hole. 3. Install the retaining ring by pressing the retaining ring into the mounting hole until fully seated. 4. Connect the electrical connector to the socket. 5. Position the socket to the retaining ring. 6. Install the socket into the retaining ring by pressing in the socket until fully seated. 7. Install the 12 volt power supply or cigar lighter fuse. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 7566 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 7575 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 7581 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start Fuse: Customer Interest Electrical - Dead Battery/No Crank/No Start TECHNICAL Bulletin No.: 08-06-03-010 Date: September 30, 2008 Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC) Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System Message (Install 125 Amp Mega Fuse) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3 Condition Some customers may comment on the following conditions: ^ The battery runs down. ^ The engine will not crank. ^ The engine will not start. ^ The Instrument Panel Cluster charge indicator turns on. ^ The Driver Information Center displays a Service Charge System message. Cause This condition may be caused by an open Mega Fuse in the underhood electrical center. Correction Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 7590 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start TECHNICAL Bulletin No.: 08-06-03-010 Date: September 30, 2008 Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC) Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System Message (Install 125 Amp Mega Fuse) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3 Condition Some customers may comment on the following conditions: ^ The battery runs down. ^ The engine will not crank. ^ The engine will not start. ^ The Instrument Panel Cluster charge indicator turns on. ^ The Driver Information Center displays a Service Charge System message. Cause This condition may be caused by an open Mega Fuse in the underhood electrical center. Correction Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 7596 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block Fuse: Locations Engine Compartment Fuse Block ENGINE COMPARTMENT FUSE BLOCK The engine compartment fuse block is located on the driver side of the engine compartment. To remove the cover, push in on the tab on the end of the cover and lift. To reinstall the cover, line up the tab and push down on the cover until the tab clicks into place. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7599 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7600 The trailer brake relay is located on the bottom side of the battery harness. FUSES ................................................................................................................................................. ..................................................................... USAGE O2 SNSR .......................................................................................................................................... Oxygen Sensors, Air Injection Reactor (AIR) Relay A/C .............................................................................................................................................................. Air Conditioning Control Head, Power Seats A/C CMPRSR ............................................................... ...................................................................................................... Air Conditioning Compressor ABS .................................................................................................... Antilock Brake System (ABS), ABS Module, Four-Wheel Drive, Gravity Sensor ABS 1 .............................................................................. ................................................................................................................... ABS 1 (ABS Logic) ABS 2 .............................................................................................................................................................. ................................... ABS 2 (ABS Pump) AUX PWR 1 ..................................................................... ................................................................................................................... Accessory Power 1 AUX PWR 2 ................................................................................................................................................. ....................................... Accessory Power 2 BCK/UP ....................................................................... .............................................................................................................................. Back-up Lights BLWR .................................................................................................................................................. .............................................. Climate Control Fan CLSTR ................................................................. ................................................................................................................................................... Cluster CNSTR VENT ......................................................................................................................... ............................................. Fuel Canister Vent Solenoid CRUISE ............................................... Cruise Control Switch, Inside Rearview Mirror, Transfer Case Control Module, Brake Switch, Clutch Disable DR/LCK .................................................................................................................................. ....................................... Power Door Locks (If Equipped) DRL ......................................................... ................................................................................................................................... Daylight Running Lamps ERLS .......................................................................................... Mass Air Flow (MAF) Sensor, Can Purge Solenoid, Air Injector Reactor (AIR) Relay ETC ....................................... ...................................................................................................................................... Electronic Throttle Control (ETC) FOG/LAMP ...................................................................................................... ......................................................................... Fog Lamps (If Equipped) FRT PRK LAMP ....................................................................... Front Park/Turn Lamps, Driver and Passenger Side Power Window Switches Lighting FRT/AXLE ..................................................................................... .................................................................................................... Front Axle Actuator FSCM .............. .............................................................................................................................................................. ....... Fuel System Control Module BACKUP LAMP ............................................................................. ............................................................................................................ Backup Lamp HORN .............. .............................................................................................................................................................. ............................................ Horn HTD/SEAT ..................................................................................... .......................................................................................... Heated Seat (If Equipped) IGN ........................................................... Ignition, Clutch Starter Switch, Neutral Safety Back-Up Switch, Ignition Coils 1-5, Air Conditioning Relay INJ ......................................................................... ............................................................................................................................................... Injectors LT HDLP .............................................................................................................................................. .......................................... Driver Side Headlamp PCM B .................................................................. ......................................................................................................... Power Control Module (PCM) B PCMI .................................................................................................................................................... ............................. Power Control Module (PCM) PWR/SEAT ...................................................................................................................................................... Power Seat Circuit Breaker (If Equipped) PWR/WNDW ..................................................................... ............................................................................................... Power Windows (If Equipped) RDO .... .............................................................................................................................................................. ........................................................ Radio REAR PRK LAMP .............................................................................................. Rear Parking Lamp 1, Passenger Side Taillamp, License Plate Lamps REAR PRK LAMP2 ................ Driver Side Rear Taillamp, Passenger Side Airbag Indicator Lighting, Instrument Panel Dimming Power (2WD/4WD switch lighting) RT HDLP ............................................................................................................................................. ..................................... Passenger Side Headlamp RVC ................................................................... ...................................................................................................................... Regulated Voltage Control S/ROOF .................................................................................................................................. ........................................................ Sunroof (If Equipped) STOP ....................................................... ........................................................................................................................................................ Stop Lamps STRTR ............................................................................................................................ ............................................................... Starter Solenoid Relay TBC ................................................ ............................................................................................................................................... Truck Body Controller TCM ........................................................................................................................... ........................................................ Transmission Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7601 TCCM .................................................................................................................................................. .............................. Transfer Case Control Module TRAILER BRAKE ................................................ ....................................................................................................................................... Trailer Brake TRANS ................................................................................................................................................ .......................................... Transmission Solenoid TRN/HAZRD FRT ..................................................................................................................................... Turn/Hazard/Courtesy/Cargo Lamps/Mirrors TRN/HAZRD REAR ...................................................... ............................................................................................................ Rear Turn/Hazard Lights VSES ................................................................................................................................................... ................. Vehicle Stability Enhancement System WPR .................................................................... ..................................................................................................................................................... Wiper WSW ......................................................................................................................................... ...................................................... Wiper/Washer Switch RELAYS .............................................................................................................................................. .................................................................... USAGE A/C CMPRSR ...................................................................................................................................... ............................... Air Conditioning Compressor BEAM SEL ............................................................ ................................................................................................................................... Beam Selection DRL ..................................................................................................................................................... ....................................... Daylight Running Lamps FOG/LAMP .......................................................... ..................................................................................................................... Fog Lamps (If Equipped) BK UP LP ............................................................................................................................................ ...................................................... Back Up Lamp HDLP ................................................................... ............................................................................................................................................ Headlamps HORN ............................................................................................................................... ......................................................................................... Horn IGN 3 HVAC ................................................................................................. Ignition 3, Climate Control, Climate Control Head Fuse, Power Seat Fuse PRK/LAMP ............................................................................................................................................. Front Parking Lamp Fuse, Rear Parking Lamps PWR/TRN ................................................................................................................ Powertrain, Electronic Throttle Control Fuse, Oxygen Sensor Fuse RAP ................................................................................ Retained Accessory Power (Power Window Fuse, Wiper/Washer Switch Fuse), Sunroof Fuse RUN/CRNK ............ Run/Crank, Airbag System Fuse, Cruise Control Fuse, Ignition Fuse, Back-Up Lamps, ABS Fuse, Front Axle, PCM-1, Injectors Fuse, Transmission Fuse, ERLS STRTR ................................................................................................................................................. ................................... Starter Relay (PCM Relay) VSES ................................................................... ................................................................................................. Vehicle Stability Enhancement System WPR ....................................................................................................................................... ................................................................. Wipers (On/Off) WPR 2 ..................................................... .......................................................................................................................................... Wiper 2 (High/Low) MISCELLANEOUS .............................................................................................................................. ................................................................. USAGE A/C CLTCH .......................................................................................................................................... ....................... Diode -- Air Conditioning, Clutch MEGA FUSE ........................................................... ......................................................................................................................................... Mega Fuse WPR .................................................................................................................................................... ....................................................... Diode -- Wiper FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse A ................................................................................................................................................. .................................................. Trailer Park Lamp Fuse B ................................................................. .......................................................................................................... Communication Interface Module Fuse C .......................................................................................................... Supplemental Inflatable Restraint System, Sensing and Diagnostic Module Fuse D ................................................ ................................................................................................................................... Trailer Auxiliary Maxi-Fuse Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7602 Fuse: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7603 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7604 Fuse Block - Underhood - Top View Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7605 Fuse Block - Underhood - Bottom View Fuse Block - Underhood X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7606 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7607 Fuse Block - Underhood X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7608 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7609 Fuse Block - Underhood X4 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7610 Fuse Block - Underhood X5 Fuse Block - Underhood X6 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7611 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7612 Fuse Block - Underhood X7 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7613 Fuse Block - Underhood X9 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 7614 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7615 Fuse: Application and ID Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7616 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7617 Fuse Block - Underhood - Top View Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7618 Fuse Block - Underhood - Bottom View Fuse Block - Underhood X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7619 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7620 Fuse Block - Underhood X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7621 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7622 Fuse Block - Underhood X4 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7623 Fuse Block - Underhood X5 Fuse Block - Underhood X6 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7624 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7625 Fuse Block - Underhood X7 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7626 Fuse Block - Underhood X9 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 7627 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views Fuse Block: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7632 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Battery Cable Harness Routing 1 - G104 2 - Starter 3 - Generator X2 4 - Battery 5 - G100 6 - Battery Negative Terminal 7 - Fuse Block - Underhood 8 - Ring Terminal Battery 9 - Ring Terminal Generator 10 - Battery Positive Terminal 11 - Generator Body Harness Routing 1 of 3 (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7633 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7634 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7635 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7636 Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 1 - G104 2 - Starter 3 - Battery 4 - G100 5 - Fuse Block - Underhood 6 - Battery Positive Terminal 7 - Generator Left and Right Sides of Engine Compartment Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 7637 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7640 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7641 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7642 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7643 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7644 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7645 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7646 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7647 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7648 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7649 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7650 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7651 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7652 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7653 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7654 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7665 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7666 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7667 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7668 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7704 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7705 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7706 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7707 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7708 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7709 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7710 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7711 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7712 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7714 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7715 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7716 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7717 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7718 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7719 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7720 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7721 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7722 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7723 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7724 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7727 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 7811 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 4. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Installation Procedure 1. Align the wiring harnesses and install the fuse relay center (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 7812 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuse relay center bolts. Tighten the relay center bolts to 6 Nm (53 lb in). 3. Install the junction block cover (2). Press downward to engage the tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7817 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7818 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7819 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7820 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7821 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7822 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 7831 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7837 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 Multiple Junction Connector: Diagrams X100 - X199 X103 Inline Harness Connector End Views X103 Forward Lamp Harness to the Body Harness X104 Inline Harness Connector End Views X104 Forward Lamp Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7840 X106 Inline Harness Connector End Views X106 Body Harness to the Chassis harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7841 X102 Inline Harness Connector End Views X102 Body Harness to the Chassis Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7842 X107 Inline Harness Connector End Views X107 Forward Lamp Harness to Right Front Turn Signal Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7843 X108 Inline Harness Connector End Views X108 Forward Lamp Harness to Left Front Turn Signal Harness X109 Inline Harness Connector End Views X109 Engine Harness to Battery Harness (K18) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7844 X110 Inline Harness Connector End Views X110 Chassis Harness to Engine Harness (UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7845 X125 Inline Harness Connector End Views X125 Engine Harness to the Body Harness X126 Inline Harness Connector End Views X126 Chassis Harness to the Engine Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7846 X175 Inline Harness Connector End Views X175 Engine Harness to Transmission Harness (M30) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7847 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7848 Multiple Junction Connector: Diagrams X200 - X299 X200 Inline Harness Connector End Views X200 I/P Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7849 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7850 X201 Inline Harness Connector End Views X201 I/P Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7851 X202 Inline Harness Connector End Views X202 Driver Door Harness to the Body Harness (AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7852 X203 Inline Harness Connector End Views X203 I/P Harness to the HVAC Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7853 X204 Inline Harness Connector End Views X204 Steering Column Harness to the I/P Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7854 X209 Inline Harness Connector End Views X209 Body Harness to the Driver Door Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7855 X211 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7856 Inline Harness Connector End Views X211 Passenger Door Harness to the Body Harness (AU3) X208 Inline Harness Connector End Views X208 I/P Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7857 X210 Inline Harness Connector End Views X210 Body Harness to the Passenger Door Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7858 X275 Inline Harness Connector End Views X275 SIR Coil Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7859 X276 Inline Harness Connector End Views X276 Body Harness to the Steering Column Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7860 Multiple Junction Connector: Diagrams X300 - X399 X307 Inline Harness Connector End Views X307 Body Harness to the Driver Seat Harness (AG1) X310 Inline Harness Connector End Views X310 Dome Lamp Harness to the Body Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7861 X311 Inline Harness Connector End Views X311 Body Harness to the Right Rear Passenger Door Harness (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7862 X312 Inline Harness Connector End Views X312 Body Harness to the Left Rear Passenger Door Harness (Extended Cab) X313 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7863 Inline Harness Connector End Views X313 Body Harness to the Passenger Seat Harness X316 Inline Harness Connector End Views X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7864 X316 Body Harness to the Left Rear Passenger Door Harness (Crew Cab without A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7865 X316 Body Harness to the Left Rear Passenger Door Harness (Extended Cab) X317 Inline Harness Connector End Views X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7866 X317 Body Harness to the Right Rear Passenger Door Harness (Crew Cab without A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7867 X317 Body Harness to the Right Rear Passenger Door Harness (Extended Cab) X318 Inline Harness Connector End Views X318 Heat Element to Passenger Seat Harness (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7868 X319 Inline Harness Connector End Views X319 Heat Element to Driver Seat Harness (AG1) X320 Inline Harness Connector End Views X320 Body Harness to Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7869 X314 Inline Harness Connector End Views X314 Body Harness to the Driver Seat Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7870 X315 Inline Harness Connector End Views X315 Body Harness to the Passenger Seat Harness (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7871 Multiple Junction Connector: Diagrams X400 - X499 X400 Inline Harness Connector End Views X400 Chassis Harness to the License Lamp Harness X403 Inline Harness Connector End Views X403 Left Rear Lamp Assembly to the Trailer Accessory Harness (Trailer Accessory) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7872 X404 Inline Harness Connector End Views X404 (UY7) Chassis Harness to License Lamp Harness X401 Inline Harness Connector End Views X401 Left Rear Lamp Assembly to the Chassis Harness (- UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7873 X401 Trailer Accessory Harness to the Chassis Harness (UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7874 X402 Inline Harness Connector End Views X402 Right Rear Lamp Assembly to the Chassis Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > X100 - X199 > Page 7875 X405 Inline Harness Connector End Views X405 (UY7) Trailer Jumper Harness to License Lamp Harness Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7880 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7881 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7890 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 7891 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7900 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7901 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7902 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7907 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7913 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7914 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7915 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7920 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7921 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7922 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7923 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7924 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7925 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7930 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7936 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7937 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7938 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7939 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7940 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7941 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 7947 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 7948 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 7949 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 7950 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 7951 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 7952 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 7953 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Fastener Tightening Specifications Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Fastener Tightening Specifications > Page 7956 Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Fastener Tightening Specifications > Page 7957 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 7960 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 7961 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 7962 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 7963 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 7964 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 7965 path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 7966 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights. 1. Make sure that the vehicle is on a level surface, such as an alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressure to the pressures shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID). 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure that the rear compartment is empty except for the spare tire. 6. Close the doors and he hood. Z Height Measurement The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Jounce the front and rear suspension to obtain at least 38 mm (1.5 in) deflection, then allow the vehicle to settle. Important: The left and right Z height difference should be no more than 12 mm (0.47 in). 1. Set the top edge of the level on the reference surface (Point A) of the steering knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 7967 2. With the level on the steering knuckle (C), extend the level directly under the rear of the rear of the front attachment bolt of the lower control arm (A). 3. While keeping the level in contact with the knuckle reference surface, adjust the level up or down until the bubble indicates it is horizontally level. 4. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your first measurement. 5. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the front end of the rear attachment bolt of the lower control arm (B). 6. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your second measurement. 7. Average the 2 readings (add them together, and then divide by 3) and this result is your final Z height number. 8. Repeat steps 1 through 7, a total of 3 times, writing down the results. 9. Average the results (add them together, and then divide by 3) and this result is your final Z height number. 10. Compare your Z height number with the Service Information Z height specification. Refer to Trim Height Specifications (See: Suspension/Specifications/Trim Height Specifications). Z Height Adjustment Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 7968 1. For vehicles equipped with a torsion bar suspension turn the torsion bar adjuster bolt (1) clockwise to raise the and counterclockwise to lower the height adjustment. 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: The left and right D height difference should be no more than 12 mm (0.47 in.) 1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. D Height shall be measured as the perpendicular distance from the inside lip of the jounce bumper cup flange to the jounce bumper contact pad, or top of the rear axle "tube" when a jounce bumper pad is not used. 5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8. Refer to Trim Height Specifications (See: Suspension/Specifications/Trim Height Specifications). 10. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) and Tire Diagnosis Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering/Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 7971 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Special Tools J 45938 Alignment Socket 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Specifications (See: Suspension/Specifications/Trim Height Specifications). For an accurate reading, do not push or pull on the tires during the alignment process. 2. Determine the caster angle (2). Be sure to compensate for frame angle where required. 3. Determine the positive camber (2) or negative camber (3) angle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 7972 4. The 4WD and 2WD Z71 vehicles are adjusted at the upper control arm. 5. The 2WD vehicles are adjusted at the lower control arm. 6. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 7. Loosen the control arm cam adjustment bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Using the J 45938 adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt in order to ensure the cam bolt position does not change while tightening the nut. * Tighten the 2WD cam nuts to 155 Nm (114 lb ft). * Tighten the 4WD cam nuts to 155 Nm (114 lb ft). 9. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications). When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 7973 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the tie rod. 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the jam nut on the tie rod to 70 Nm (52 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Page 7974 Alignment: Tools and Equipment Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 7992 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 7993 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 7994 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 7995 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 7996 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 7997 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8004 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8005 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8006 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8007 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8008 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8009 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8015 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8016 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8017 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8018 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8019 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8022 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the body control module (BCM) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8023 Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement Tire Valve Stem Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8024 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the lower control arm with a suitable jack. Note: In the following service procedure, it is NOT necessary to separate the brake caliper and mounting bracket. Remove them as an assembly. Support the assembly with mechanics wire or equivalent. 4. Remove the brake caliper assembly and relocate to the side. Refer to Brake Caliper Bracket Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement). Note: Perform the following service procedure if the vehicle is equipped with 4WD. If the vehicle does not have 4WD, proceed to Step 6. 5. Separate the front wheel drive shaft from the steering knuckle. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 6. Remove the speed senor wiring harness from the retaining clips on the upper control arm and frame. 7. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 8. Separate the upper ball joint from the knuckle. Refer to Upper Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Suspension/Ball Joint/Service and Repair/Front Suspension/Upper Control Arm Ball Joint Replacement)Upper Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Suspension/Ball Joint/Service and Repair/Upper Control Arm Ball Joint Replacement). 9. Separate the lower ball joint from the knuckle. Refer to Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Suspension/Ball Joint/Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Suspension/Ball Joint/Service and Repair/Front Suspension/Lower Control Arm Ball Joint Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 8029 Note: Remove the wheel hub and bearing assembly and knuckle as a unit. 10. Remove the knuckle from the upper and lower control arms. 11. Remove the wheel hub and bearing assembly from the knuckle. Refer to Front Wheel Bearing and Hub Replacement (See: Suspension/Wheel Bearing/Service and Repair). Installation Procedure 1. Install the wheel hub and bearing assembly onto the knuckle. Refer to Front Wheel Bearing and Hub Replacement (See: Suspension/Wheel Bearing/Service and Repair). 2. Install the lower control arm/ball joint into the knuckle. Refer to Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Suspension/Ball Joint/Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Suspension/Ball Joint/Service and Repair/Front Suspension/Lower Control Arm Ball Joint Replacement). Note: The following service procedure is for vehicles equipped with 4WD only. If the vehicle is not equipped with 4WD, proceed to Step 4. 3. Install the wheel drive shaft into the knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 8030 4. Install the upper control arm/ball joint into the knuckle. Refer to Upper Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Suspension/Ball Joint/Service and Repair/Front Suspension/Upper Control Arm Ball Joint Replacement)Upper Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Suspension/Ball Joint/Service and Repair/Upper Control Arm Ball Joint Replacement). 5. Install the outer tie rod end into the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 6. Install the speed senor wiring harness in the retaining clips on the upper control arm and frame. 7. Install the brake caliper mounting bracket. Refer to Brake Caliper Bracket Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement). 8. Install the wheel drive shaft retaining nut to specifications. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 9. Remove the support from the lower control arm. 10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) 11. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: * Use clean, new power steering fluid type only. See the Maintenance and Lubrication subsection for fluid specifications. Refer to Fluid and Lubricant Recommendations (See: Maintenance/Service Intervals). * Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. * Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. Important: Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 1. Start the engine. 2. Firmly apply the brake pedal 10-15 times. 3. Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. Vehicles equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operating specification. Refer to Checking and Adding Power Steering Fluid (See: Service and Repair/Checking and Adding Power Steering Fluid). 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations Power Steering Fluid Reservoir: Locations Power Steering Pump Disassembled View 1 - Hydraulic Pump Reservoir Assembly (Typical) 2 - Reservoir Capstick Assembly 3 - O-Ring Seal 4 - Flow Control Spring 5 - Control Valve Assembly 6 - O-Ring Seal 7 - O-Ring Union Fitting 8 Hydraulic Pump Housing Assembly 9 - Reservoir Retaining Clip (RH) 10 - Reservoir Retaining Clip (LH) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 8041 Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service Precautions > Page 8045 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet and Outlet Hose Replacement (LH8) (5.3L) Removal Procedure 1. Remove as much power steering fluid from the power steering fluid reservoir as possible. 2. Remove the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 3. Place drain pans under the vehicle as needed. 4. Disconnect the power steering gear inlet and outlet hose (1) from the power steering pump and power steering fluid reservoir assembly. 5. Remove the power steering gear inlet and outlet hose bracket bolts (2). 6. Remove the power steering gear inlet and outlet hose retaining plate bolt (1). 7. Disconnect the power steering gear inlet and outlet hose (3) from the steering gear and remove it from the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service Precautions > Page 8046 8. Clean the power steering gear inlet and outlet hose ports at the steering gear of any debris. 9. Transfer any parts as needed. Installation Procedure 1. Install the power steering gear inlet and outlet hose (3) to the vehicle and connect it to the steering gear. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the power steering gear inlet and outlet hose retaining plate bolt (1) and tighten to 12 Nm (106 lb in). 3. Install the power steering gear inlet and outlet hose bracket bolts (2) and tighten to 9 Nm (80 lb in). 4. Connect the power steering gear inlet and outlet hose (1) to the power steering pump and power steering fluid reservoir assembly. Tighten the fitting to 25 Nm (18 lb ft). 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Install the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 7. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle Disassembly Procedure 1. Remove the O-ring union fitting (5) from the hydraulic pump housing assembly (1). 2. Remove the O-ring seal (4) from the O-ring union fitting (5). 3. Remove the control valve assembly (3). 4. Remove the flow control spring (2). Assembly Procedure 1. Install the flow control spring (2) to the hydraulic pump housing assembly (1). 2. Install the control valve assembly (3). 3. Lubricate the new O-ring seal (4) with power steering fluid. 4. Install the O-ring seal (4) on to the O-ring union fitting (5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the O-ring union fitting (5) into the hydraulic pump housing assembly (1). Tighten the O-ring union fitting to 75 Nm (55 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Power Steering Pump Seal > Component Information > Service and Repair Power Steering Pump Seal: Service and Repair Power Steering Pump Shaft Seal Replacement Removal Procedure 1. Remove the power steering pump from the vehicle, if necessary. Refer to Power Steering Pump Replacement (LLV, LLR) (See: Service and Repair)Power Steering Pump Replacement (LH8) (See: Service and Repair). Important: Protect the drive shaft with the shim stock. 2. Use a small chisel in order to remove the seal. Discard the seal. Installation Procedure 1. Lubricate the new drive shaft seal using power steering fluid. 2. Use a deep socket in order to install the new drive shaft seal. 3. Install the power steering pump, if removed. Refer to Power Steering Pump Replacement (LLV, LLR) (See: Service and Repair)Power Steering Pump Replacement (LH8) (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8064 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8065 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8066 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8067 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8068 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8069 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8075 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8076 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8077 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8078 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8079 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8080 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 8085 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Diagrams Steering Gear: Diagrams Power Steering Gear Disassembled View Rack and Pinion Power Steering Gear 1 - Hexagon Torque Prevailing Nut 2 - Tie Rod Seal 3 - Outer Tie Road Assembly 4 - Hexagon Jam Nut 5 - Tie Rod End Clamp 6 - Rack and Pinion Boot 7 - Boot Clamp 8 - Inner Tie Rod Assembly 9 - Shock Dampener Ring 10 - Adjuster Plug Lock Nut 11 - Cylinder Line Assembly (RH) 12 - Cylinder Line Assembly (LH) 13 - O-Ring Seal 14 - O-Ring Seal 15 - Rack and Pinion Gear Assembly (Partial) 16 - Needle Bearing Annulus Assembly 17 - Seal Adapter 18 - Retaining Ring 19 - Spool Shaft Seal 20 - Hexagon Lock Nut 21 - Dust Cover 22 - Shock Dampener Ring 23 Inner Tie Rod Assembly 24 - Breather Tube 25 - Boot Clamp 26 - Rack and Pinion Boot 27 - Tie Rod End Clamp 28 - Hexagon Jam Nut 29 - Outer Tie Rod Assembly 30 - Tie Rod Seal 31 Hexagon Torque Prevailing Nut Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle Steering Gear: Service and Repair Steering Gear Boot and Breather Tube Replacement - Off Vehicle Steering Gear Boot and Breather Tube Replacement - Off Vehicle Tools Required J 22610 Keystone Clamp Pliers. Disassembly Procedure 1. To remove the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 2. Remove the hexagon jam nut (2) from the inner tie rod assembly (1). 3. Remove the tie rod end clamp (2) from the rack and pinion boot (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8091 4. Remove the boot clamp (1) from the rack and pinion boot with side cutters. 5. Discard the boot clamp (1). Important: * If a breather tube is present, mark the location of the breather tube on the gear assembly before removal of the rack and pinion boot. * After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 6. Remove the rack and pinion boot (1) and the breather tube, if present, from the rack and pinion gear assembly. Assembly Procedure 1. Install the new boot clamp (1) onto the rack and pinion boot (3). 2. Prior to rack and pinion boot installation, apply grease to the inner tie rod assembly (2) and the rack and pinion gear assembly (1). 3. Install the rack and pinion boot (3) onto the inner tie rod assembly (2). 4. If present, install the breather tube while aligning the breather tube with the mark made during removal and the molded nipple of the rack and pinion boot. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8092 Important: The rack and pinion boot (3) must not be twisted, puckered or out of shape in any way. If the rack and pinion boot (3) is not shaped properly, adjust the rack and pinion boot (3) by hand before installing the boot clamp. 5. Install the rack and pinion boot onto the gear assembly (1) until the rack and pinion boot (3) is seated in the gear assembly groove. 6. Install the boot clamp (1) on the rack and pinion boot (2) with J 22610 . 7. Crimp the boot clamp (1). 8. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end clamp. 9. Install the tie rod end clamp (2) onto the rack and pinion boot (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8093 10. Install the hexagon jam nut (2) to the inner tie rod assembly (1). 11. To assemble the outer tie rod assembly. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8094 Steering Gear: Service and Repair Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle Disassembly Procedure 1. Loosen both cylinder line fittings on the cylinder end of the gear assembly. 2. Loosen both fittings on the cylinder line assemblies (1) at the valve end of the gear assembly. 3. Remove both cylinder line assemblies (1) from the rack and pinion gear assembly (2). 4. Remove the O-ring seals (1) from the valve end of line. 5. Discard the O-ring seals (1). Assembly Procedure 1. Inspect the cylinder lines (1) for the following items: * Cracks * Dents * Damage to the threads 2. Replace the parts as needed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8095 3. Install the new O-ring seals (1) to the valve end of the cylinder lines. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the cylinder line assemblies (1) to the gear assembly (2). * Tighten the valve end fittings to 15 Nm (11 lb ft). * Tighten the cylinder end fittings to 15 Nm (11 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8096 Steering Gear: Service and Repair Steering Gear Rack Bearing Preload Adjustment - Off Vehicle Steering Gear Rack Bearing Preload Adjustment - Off Vehicle Special Tools J 45059 Angle Meter 1. Loosen the adjuster plug lock nut (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the adjuster plug. For vehicles with allen head adjuster plug: * Tighten the adjuster plug to 15 Nm (11 lb ft). * Use J 45059 to back off the adjuster plug 25 degrees. For vehicles with hex head adjuster plug: * Tighten the adjuster plug to 12 Nm (106 lb in). * Use J 45059 to back off the adjuster plug 105 degrees. 3. Tighten the adjuster plug lock nut (1) to the steering gear housing. Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) to 60 Nm (44 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8097 Steering Gear: Service and Repair Steering Gear Replacement Steering Gear Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove both of the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the engine protection shield if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 4. Disconnect the outer tie rod end from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 5. Place a drain pan to catch the fluid. 6. Disconnect the power steering hose assembly from the steering gear. Refer to Power Steering Gear Inlet and Outlet Hose Replacement (LLV, LLR) (See: Power Steering/Power Steering Line/Hose/Service and Repair)Power Steering Gear Inlet and Outlet Hose Replacement (LH8) (See: Power Steering/Power Steering Line/Hose/Service and Repair). 7. Remove the coupler clamp bolt from the intermediate shaft. Refer to Lower Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Lower Intermediate Steering Shaft Replacement). 8. Separate the intermediate shaft from the steering gear. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8098 9. Remove the steering gear vertical mounting nuts, the washers and the bolts. 10. Remove the steering gear horizontal mounting nuts, the washers and the bolts. 11. Remove the crossmember, 2WD ONLY. Refer to Crossmember Replacement (See: Suspension/Cross-Member/Service and Repair/Crossmember Replacement). 12. Remove the steering gear from the vehicle. Installation Procedure 1. Install the steering gear into the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8099 2. Loose install the steering gear horizontal mounting nuts, the washers and the bolts. 3. Install the crossmember, 2WD ONLY. Refer to Crossmember Replacement (See: Suspension/Cross-Member/Service and Repair/Crossmember Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Loose install the steering gear vertical mounting nuts, the washers and the bolts. * Tighten the long bolts to 130 Nm (96 lb ft). * Tighten the isolator clamp bolts to 100 Nm (74 lb ft). 5. Install the intermediate shaft to the steering gear. 6. Install the coupler clamp bolt to the intermediate shaft. Refer to Lower Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Lower Intermediate Steering Shaft Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot and Breather Tube Replacement - Off Vehicle > Page 8100 7. Connect the power steering hose assembly to the steering gear. Refer to Power Steering Gear Inlet and Outlet Hose Replacement (LLV, LLR) ( See: Power Steering/Power Steering Line/Hose/Service and Repair)Power Steering Gear Inlet and Outlet Hose Replacement (LH8) (See: Power Steering/Power Steering Line/Hose/Service and Repair). 8. Install the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 9. Install the outer tie rod end to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 10. Install both of the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 11. Lower the vehicle. 12. Bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering/Power Steering Bleeding/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement Steering Shaft: Service and Repair Steering Shaft Upper Bearing Replacement Steering Shaft Upper Bearing Replacement Removal Procedure 1. Remove the steering column tilt head housing. Refer to Steering Column Tilt Head Housing Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Head Housing Replacement). 2. Remove the steering shaft upper bearing from the steering column tilt head housing. Installation Procedure 1. Install the steering shaft upper bearing into the steering column tilt head housing. 2. Install the steering column tilt head housing. Refer to Steering Column Tilt Head Housing Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Head Housing Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 8105 Steering Shaft: Service and Repair Steering Shaft Replacement (Tilt Column) Steering Shaft Replacement (Tilt Column) Removal Procedure 1. Remove the steering column tilt head housing. Refer to Steering Column Tilt Head Housing Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Head Housing Replacement). 2. Remove the steering column shaft. Installation Procedure 1. Install the steering column shaft. 2. Install the steering column tilt head housing. Refer to Steering Column Tilt Head Housing Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Head Housing Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation Steering Wheel: Description and Operation Steering Wheel and Column Description and Operation The steering wheel and column has 4 primary functions: * Vehicle steering * Vehicle security * Driver convenience * Driver safety Vehicle Steering The steering wheel is the first link between the driver and the vehicle. The steering wheel is fastened to a steering shaft within the column. At the lower end of the column, the intermediate shaft connects the column to the steering gear. Vehicle Security, Found on Some Vehicle Models Theft deterrent components are mounted and designed into the steering column. The following components allow the column to be locked in order to minimize theft: * The ignition switch-location varies * The steering column lock-content varies * The ignition cylinder-location varies * The theft deterrent module-location varies Driver Convenience The steering wheel and column may also have driver controls attached for convenience and comfort. The following controls may be mounted on or near the steering wheel or column. * The turn signal switch * The hazard switch * The headlamp dimmer switch * The wiper/washer switch * The horn pad/cruise control switch * The redundant radio/entertainment system controls * The manual/power tilt or tilt/telescoping functions * The power pedal adjustment control switch * The navigation/OnStar(R) features * The HVAC controls Driver Safety The steering wheel and column has safety features to protect the driver. The following components may be mounted on or near the steering column: Energy-Absorbing Steering Column - The energy-absorbing steering column compresses in the event of a front-end collision, which reduces the chance of injury to the driver. The energy-absorbing feature, collapsible steering shaft, and break away mounting features help reduce the injury in the event of an accident. In addition to these features, the following driver safety features may be on the steering column. To inspect the steering column for damage, refer to Steering Column Accident Damage Inspection (See: Steering Column/Testing and Inspection/Initial Inspection and Diagnostic Overview/Steering Column Accident Damage Inspection). Electronic Park Lock (EPL)/Ignition Lock Cylinder Control Actuator - If the vehicle is equipped with automatic transmission and a floor mounted console gear shift, it has an ignition lock cylinder control actuator system in the steering column. The ignition lock cylinder control actuator purpose is to prevent the ignition key from being turned to the OFF position when the transmission is in any position other than PARK and the vehicle may still be moving. The column ignition lock system consists of an ignition lock cylinder control actuator, and a park position switch that is located in the automatic transmission shift lock control switch. The ignition lock cylinder control actuator contains a pin that is spring loaded to mechanically prevent the ignition key cylinder from being turned to the lock position when the vehicle transmission is not in the PARK position. If vehicle power is lost, and/or the transmission is not in the PARK position the operator will not be able to turn the ignition key to the lock position and will not be able to remove the ignition key from the column. Linear Shift Assembly - If the vehicle is equipped with a column mounted gear shift, it has a linear shift assembly on the steering column. The linear shift assembly has a cable that runs from the linear shift assembly to the ignition lock cylinder case. The purpose of this cable is to prevent the ignition key from being turned to the OFF position when the transmission is in gear and the vehicle may still be moving. The linear shift assembly cable contains a pin that Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Page 8109 is spring loaded to mechanically prevent the ignition key cylinder from being turned to the lock position when the vehicle transmission is not in the PARK position. If vehicle power is lost, and/or the transmission is not in the PARK position the operator will not be able to turn the ignition key to the lock position and will not be able to remove the ignition key from the column. SIR Coil and Module - For additional information on the operation of the SIR coil and module, refer to SIR System Description and Operation (See: Restraint Systems/Air Bag Systems/Description and Operation). Automatic Transmission Shift Lock Actuator - The automatic transmission shift lock control system is a safety device that prevents an inadvertent shift out of PARK when the engine is running. The driver must press the brake pedal before moving the shift lever out of the PARK position. The system consists of the following components: the automatic transmission shift lock control solenoid, the automatic transmission shift lock control switch, the body control module (BCM), the powertrain control module (PCM)/engine control module (ECM). With the ignition in the ON position, voltage is supplied to automatic transmission shift lock control switch. Voltage flows through the normally closed contacts of the automatic transmission shift lock control switch to the automatic transmission shift lock control solenoid. When the BCM receives a class 2 message from the PCM/ECM indicating the transmission is in the park position the BCM then grounds the automatic transmission shift lock solenoid control circuit. This energizes the automatic transmission shift lock control solenoid causing the transmission shift lever to be physically locked in the PARK position. When the brake pedal is pressed the contacts in the automatic transmission shift lock control switch open, de-energizing the automatic transmission shift lock control solenoid. This allows the shift lever to be move out of the PARK position. Steering Wheel Angle Sensor or Steering Wheel Position Sensor - The steering wheel position sensor is located somewhere along the steering shaft assembly. The sensor measures the position of the steering wheel and the speed at which it is rotated. A signal representing this measurement is provided to the vehicle stability enhancement system (VSES) module. The VSES module uses this signal, along with several others representing different vehicle conditions, to monitor the driving behavior of the vehicle and ensure that it stays in control. If the VSES module determines that the vehicle is out of control it provides signals to the powertrain control module (PCM) and the ABS module. These output signals are used to modulate the transmission torque and brake pressure of each of the vehicles wheels in order to regain control of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Page 8110 Steering Wheel: Service and Repair Steering Wheel Replacement Special Tools J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Lock the steering column through the access hole in the lower steering column trim cover using anti-rotation pin J 42640 . 3. Remove the inflatable restraint steering wheel module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 4. Make alignment marks in order to note the relationship between the steering wheel and the steering shaft. 5. Loosen the steering wheel nut 2 complete rotations. 6. Carefully pull on the steering wheel until it comes loose from the steering column. 7. Remove the steering wheel nut (2). 8. Remove the steering wheel from the steering column using caution to guide the electrical connectors (1,3) through it without damaging them. Installation Procedure Caution: Improper alignment of the steering wheel to the steering column shaft will cause vehicle damage. In order to prevent vehicle damage, ensure that the steering wheel is properly indexed to the steering column before tightening the steering wheel nut. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Page 8111 1. If installing a new steering wheel perform the following: 1. Ensure the front wheels are still set in the straight-ahead position. 2. Position the steering wheel near the steering shaft with the arrow (1) at the 12 o'clock position. 3. Ensure that proper tooth alignment between the steering wheel and the steering shaft has been achieved (2). 2. If installing the original steering wheel perform the following: 1. Position the steering wheel to the steering column. 2. Align the marks made during the removal of the steering wheel. 3. Ensure the electrical connectors (1,3) are not pinched between the steering column and the steering wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the steering wheel nut (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Page 8112 Tighten the nut to 35 Nm (26 lb ft). 5. Install the inflatable restraint steering wheel module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 6. Remove anti-rotation pin J 42640 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection Tie Rod: Testing and Inspection Steering Linkage Inner Tie Rod Inspection Steering Linkage Inner Tie Rod Inspection Special Tools J 8001 Dial Indicator Set 1. Turn the ignition key to the on position with the engine off. 2. With the aid of an assistant, turn the steering wheel to the full stop position and hold it in that position until the test is complete. The tie rod being tested should be inside the steering gear housing seated against the steering stop. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. If there is not a good location for the dial indicator pointer at the steering gear housing, install a large worm gear hose clamp to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the dial indicator pointer. 5. Install a dial indicator between the inner tie rod (2) and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 8117 Important: Only move the tire enough to feel any lash between the inner tie rod and the inner tie rod housing without moving the steering gear rack. 6. Grasping the tire at the 3 o'clock and 9 o'clock positions, gently push in on one side of the tire to remove any lash. 7. Zero the dial indicator. 8. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 9. Record the measurement seen on the dial indicator. 10. If the measured value exceeds 0.5 mm (0.02 in) then replace the inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Magnasteer) (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Magnasteer))Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet Valve) (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet Valve)). 11. Repeat the procedure for the other side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 8118 Tie Rod: Testing and Inspection Steering Linkage Outer Tie Rod Inspection Steering Linkage Outer Tie Rod Inspection Special Tools J 8001 Dial Indicator Set 1. Inspect the outer tie rod end seal. If the outer tie rod end seal is torn, replace the outer tie rod end. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Install dial indicator J 8001 or equivalent between the outer tie rod end and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the dial indicator position. 4. Grasping the tire at the 3 o'clock and 9 o'clock positions, gently push in on one side of the tire to remove any lash. 5. Zero the dial indicator. 6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 7. Record the measurement seen on the dial indicator. 8. Movement should not exceed 0.5 mm (0.02 in). If the movement exceeds 0.5 mm (0.02 in) then replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 9. Repeat this procedure for the other side of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement Tie Rod: Service and Repair Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement Special Tools J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the outer tie rod retaining nut. Discard the nut. Caution: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. 4. Disconnect the outer tie rod from the steering knuckle using J 24319-B . 5. Loosen the jam nut and remove the outer tie rod from the inner tie rod. Discard the jam nut. 6. Clean the tapered surface of the steering knuckle. Installation Procedure 1. Lubricate the inner tie rod threads with a suitable chassis lubricant before installing the outer tie rod. 2. Install the NEW jam nut to the outer tie rod. 3. Install the outer tie rod to the inner tie rod. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8121 4. Install the outer tie rod to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the NEW outer tie rod retaining nut. * Tighten the outer tie rod retaining nut to 45 Nm (33 lb ft) plus 95 degrees. * Tighten the outer tie rod end jam nut to 70 Nm (52 lb ft). 6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. Adjust the front toe. Refer to Wheel Alignment Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8122 Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Magnasteer) Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Magnasteer) Special Tools J 34028 Inner Tie Rod Wrench Disassembly Procedure Note: After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 1. To remove the rack and pinion boot, refer to Steering Gear Boot and Breather Tube Replacement - Off Vehicle (See: Steering Gear/Service and Repair). 2. Place the gear in a vise. Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. 3. Remove the shock dampener (6) from the inner tie rod housing (4). 4. Slide the shock dampener (6) back on the rack (5). Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (4). 6. Place a wrench on the flats of the inner tie rod housing (4). 7. Rotate the inner tie rod housing (4) counterclockwise, while holding the rack stationary, until the inner tie rod separates from the rack (5). 8. Remove the shock dampener (3) from the inner tie rod housing (2). 9. Slide the shock dampener (3) back on the rack (5). Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 10. Place a pipe wrench on the rack. 11. Place a wrench on the flats of the inner tie rod housing (2). 12. Rotate the inner tie rod housing (2) counterclockwise, while holding the rack stationary, until the inner tie rod (1) separates from the rack (5). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8123 13. If female rack (1) and male inner tie rod (3), remove the old LOCTITE(R) from the threads (2) of the inner tie rod (3) and the rack (1). If male rack (5) and female inner tie rod (4) LOCTITE(R) will not be present. Assembly Procedure 1. Slide the shock dampener (4) forward onto the rack (3). Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R), or equivalent, container for expiration date. Use only enough LOCTITE(R) to evenly coat threads. If male rack (3) and female inner tie rod (2) do not apply LOCTITE(R). 2. If female rack (3) and male inner tie rod (2), apply LOCTITE(R) 262, or equivalent, to the inner tie rod threads. 3. Attach the inner tie rod onto the rack (3). Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2). Tighten the inner tie rod to 100 Nm (74 lb ft). 6. Slide the shock dampener (2) forward onto the rack. Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R), or equivalent, container for expiration date. Use only enough LOCTITE(R) to evenly coat threads. If male rack and female inner tie rod (1) do not apply LOCTITE(R). 7. If female rack and male inner tie rod (1), apply LOCTITE(R) 262, or equivalent, to the inner tie rod threads. 8. Attach the inner tie rod (1) onto the rack. Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8124 9. Place a pipe wrench on the rack next to the inner tie rod housing (4). 10. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7). Tighten the inner tie rod to 100 Nm (74 lb ft). 11. Place the inner tie rod assembly (2) in a vise. Note: If female rack (1) and male inner tie rod (2) do not stake. If male rack (1) and female inner tie rod (2) you must stake. 12. Stake both sides of the female inner tie rod assembly housing to the male rack (1). 13. Insert a 0.25 mm gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler gage (1) must not pass between the rack and the housing stake. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8125 14. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener (2) bottoms against the inner tie rod housing (3). 15. To assemble the rack and pinion boot. Refer to Steering Gear Boot and Breather Tube Replacement - Off Vehicle (See: Steering Gear/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8126 Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet Valve) Steering Linkage Inner Tie Rod Replacement - Off Vehicle (Quiet Valve) Disassembly Procedure Note: After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 1. Remove the rack and pinion boot. Refer to Steering Gear Boot and Breather Tube Replacement - Off Vehicle (See: Steering Gear/Service and Repair). 2. Place the gear in a vise. Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. 3. Remove the shock dampener (4) from the inner tie rod assembly (6). 4. Slide the shock dampener (4) back on the rack (5). Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (6). 6. Place a wrench on the flats of the inner tie rod housing (6). 7. Rotate the inner tie rod housing (6) counterclockwise, while holding the rack stationary, until the inner tie rod separates from the rack (5). Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. 8. Remove the shock dampener (3) from the inner tie rod housing (2). 9. Slide the shock dampener (3) back on the rack (5). Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 10. Place a pipe wrench on the rack. 11. Place a wrench on the flats of the inner tie rod housing (2). 12. Rotate the inner tie rod housing (2) counterclockwise, while holding the rack stationary, until the inner tie rod (1) separates from the rack (5). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8127 13. If female rack (1) and male inner tie rod (3), remove the old LOCTITE(R) from the threads (2) of the inner tie rod and the rack. If male rack (5) and female inner tie rod (4) LOCTITE(R) will not be present. Assembly Procedure 1. Slide the shock dampener (4) forward onto the rack (3). Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R) or equivalent container for expiration date. Use only enough LOCTITE(R) to evenly coat threads. If male rack (3) and female inner tie rod (2) do not apply LOCTITE(R). 2. If female rack (3) and male inner tie rod (2), apply LOCTITE(R) 262 or equivalent to the inner tie rod threads. 3. Attach the inner tie rod onto the rack (3). Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2). Tighten the inner tie rod to 100 Nm (74 lb ft). 6. Slide the shock dampener (2) forward onto the rack. Note: Threads must be clean prior to LOCTITE(R) application. Check LOCTITE(R) or equivalent container for expiration date. Use only enough LOCTITE(R) to evenly coat threads. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8128 If male rack and female inner tie rod (1) do not apply LOCTITE(R). 7. If female rack and male inner tie rod (1), apply LOCTITE(R) 262 or equivalent to the inner tie rod threads. 8. Attach the inner tie rod (1) onto the rack. Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 9. Place a pipe wrench on the rack next to the inner tie rod housing (4). 10. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7). Tighten the inner tie rod to 100 Nm (74 lb ft). 11. Place the inner tie rod assembly (2) in a vise. Note: If female rack (1) and male inner tie rod (2) do not stake. If male rack (1) and female inner tie rod (2) you must stake. 12. Stake both sides of the female inner tie rod assembly housing to the male rack. 13. Insert a 0.25 mm gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler gage (1) must not pass between the rack and the housing stake. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 8129 14. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener (2) bottoms against the inner tie rod housing (3). 15. To assemble the rack and pinion boot. Refer to Steering Gear Boot and Breather Tube Replacement - Off Vehicle (See: Steering Gear/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Upper Ball Joint Maximum Allowable Ball Joint Movement ............................................................................................................................................. 0.50 mm (0.020 in) Lower Ball Joint Maximum Allowable Ball Joint Movement ............................................................................................................................................. 0.50 mm (0.020 in) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) Ball Joint: Testing and Inspection Ball Joint Inspection (Lower Ball Joint) Ball Joint Inspection (Lower Ball Joint) Special Tools J 8001 - Dial Indicator Set Note: * The vehicle must rest on a level surface. * The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Service and Repair/Front Suspension/Lower Control Arm Ball Joint Replacement). 3. Support the lower control arm with a floor stand as far outboard as possible and raise suspension to just below the ride height. 4. Install the J 8001 - indicator , or suitable dial indicator in a way to measure the vertical lash in the ball joint. Caution: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). Gently lift or pry the suspension to induce ball joint movement. 5. If the dial indicator is reading more than 0.50 mm (0.020 in) replace the lower ball joint. Refer to Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Service and Repair/Front Suspension/Lower Control Arm Ball Joint Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) > Page 8136 Ball Joint: Testing and Inspection Ball Joint Inspection (Upper Ball Joint) Ball Joint Inspection (Upper Ball Joint) Special Tools J 8001 - Dial Indicator Set Note: * The vehicle must rest on a level surface. * The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Upper Control Arm Replacement (2WD, Z85, ZQ8) (See: Control Arm/Service and Repair/Front Suspension/Upper Control Arm Replacement)Upper Control Arm Replacement (4WD, 2WD, Z71) (See: Control Arm/Service and Repair/Upper Control Arm Replacement). 3. Support the lower control arm with a floor stand as far outboard as possible and raise the suspension to just below ride height. 4. Install J 8001 - indicator , or suitable dial indicator in a way to measure the vertical lash in the ball joint. Caution: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 5. Apply downward force to the upper control arm and zero the indicator. 6. Apply upward force to the upper control arm and check the dial indicator. 7. If the dial indicator reading is more than 0.50 mm (0.020 in) , replace the upper control arm. Refer to Upper Control Arm Replacement (2WD, Z85, ZQ8) (See: Control Arm/Service and Repair/Front Suspension/Upper Control Arm Replacement)Upper Control Arm Replacement (4WD, 2WD, Z71) (See: Control Arm/Service and Repair/Upper Control Arm Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Ball Joint: Service and Repair Front Suspension Lower Control Arm Ball Joint Replacement Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) Removal Procedure 1. Remove the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering Knuckle/Service and Repair). 2. Remove the ball joint nuts and bolts from the lower control arm. Discard the nuts and bolts. 3. Remove the ball joint from the lower control arm. Installation Procedure 1. Install the ball joint to the lower control arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 8139 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the new ball joint nuts and bolts to the lower control arm and tighten the nuts to 60 Nm (44 lb ft). 3. Install the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering Knuckle/Service and Repair). 4. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications). Upper Control Arm Ball Joint Replacement Upper Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) Special Tools J-42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the lower control arm with a suitable jack stand. 4. Disconnect the front brake hose from the upper control arm. Refer to Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement). 5. Remove the wheel speed sensor bracket bolt. 6. Disconnect the wheel speed sensor brackets. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 8140 7. Remove the nut from the upper ball joint. Discard the nut. 8. Disconnect the ball joint from the steering knuckle using the J-42188-B . 9. Remove the ball joint nuts and bolts from the upper control arm. Discard the nuts and bolts. 10. Remove the ball joint from the upper control arm. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 8141 1. Install the ball joint to the upper control arm. 2. Install the replacement bolts to the upper control arm. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the nuts to the bolts and tighten 16 Nm (12 lb ft). 4. Connect the ball joint to the steering knuckle. 5. Install the new nut to the upper ball joint and tighten to 100 Nm (74 lb ft). 6. Connect the wheel speed sensor brackets. 7. Install the wheel speed sensor bracket bolt and tighten to 20 Nm (15 lb ft). 8. Connect the front brake hose to the upper control arm. Refer to Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement). 9. Remove the support from the lower control arm. 10. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 11. Lower the vehicle. 12. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 8142 Ball Joint: Service and Repair Lower Control Arm Ball Joint Replacement Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71) Removal Procedure 1. Remove the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering Knuckle/Service and Repair). 2. Remove the ball joint nuts and bolts from the lower control arm. Discard the nuts and bolts. 3. Remove the ball joint from the lower control arm. Installation Procedure 1. Install the ball joint to the upper control arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 8143 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the new ball joint nuts and bolts to the lower control arm and tighten to 64 Nm (47 lb ft). 3. Install the steering knuckle. Refer to Steering Knuckle Replacement (See: Front Steering Knuckle/Service and Repair). 4. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 8144 Ball Joint: Service and Repair Upper Control Arm Ball Joint Replacement Upper Control Arm Ball Joint Replacement (4WD, 2WD, Z71) Special Tools J-42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the lower control arm with a suitable jack stand. 4. Disconnect the front brake hose from the upper control arm. Refer to Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement). 5. Remove the wheel speed sensor bracket bolt. 6. Disconnect the wheel speed sensor brackets. 7. Disconnect the upper control arm from the ball stud by removing the retention nuts. Discard the nuts. 8. Remove the nut from the upper ball joint. Discard the nut. 9. Disconnect the ball joint from the steering knuckle using the J-42188-B . 10. Remove the ball joint from the steering knuckle. Installation Procedure 1. Install the ball joint to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the new nut to the upper ball joint and tighten to 75 Nm (55 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 8145 3. Connect the upper control arm to the ball stud by installing the retention nuts. Tighten the nut to 47 Nm (35 lb ft). 4. Connect the wheel speed sensor brackets. 5. Install the wheel speed sensor bracket bolt and tighten to 20 Nm (15 lb ft). 6. Connect the front brake hose to the upper control arm. Refer to Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 8. Remove the lower control arm support. 9. Lower the vehicle. 10. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair Front Lower Control Arm Bushing Replacement Tools Required J 41805 Ball Joint Remover/Installer Removal Procedure 1. Remove the front drive axle, if equipped. Refer to Differential Carrier Assembly Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Carrier/Service and Repair). 2. Remove the lower control arm. Refer to Lower Control Arm Replacement (2WD, Z85, ZQ8) (See: Service and Repair/Front Suspension/Lower Control Arm Replacement). 3. Before removing the bushing, measure and record the distance from the bushing flange to the bracket. This will be the distance that the new bushing will be installed to. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 8150 4. Using the J 41805 (1), remove the rear bushing. Installation Procedure 1. Using the J 41805 (1), install the rear bushing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 8151 2. Install the rear bushing to the predetermined measurement taken earlier. 3. Install the lower control arm. Refer to Lower Control Arm Replacement (2WD, Z85, ZQ8) (See: Service and Repair/Front Suspension/Lower Control Arm Replacement). 4. Install the front drive axle, if equipped. Refer to Differential Carrier Assembly Replacement (See: Transmission and Drivetrain/Differential Assembly/Differential Carrier/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement Cross-Member: Service and Repair Crossmember Replacement Crossmember Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the crossmember mounting nuts and bolts. 3. Remove the crossmember from the vehicle. Installation Procedure 1. Install the crossmember to the vehicle. 2. Perform the following procedure before installing the bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 8156 * Remove all traces of the original adhesive patch. * Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. * Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts and the nuts and tighten to 60 Nm (44 lb ft). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 8157 Cross-Member: Service and Repair Transmission Support Crossmember Replacement Transmission Support Crossmember Replacement (2WD) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the transmission with a suitable stand or jack. 3. Remove the nuts retaining the transmission mount to the transmission support. Refer to Transmission Mount Replacement (2WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission. 4. Raise the transmission. 5. Remove the vertical bolts retaining the transmission support to the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 8158 6. Remove the horizontal nuts and the bolts retaining the transmission support to the frame. 7. Remove the transmission support from the frame. Installation Procedure 1. Install the transmission support to the frame. 2. Loose install the horizontal nuts and the bolts retaining the transmission support to the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 8159 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Loose install the vertical bolts retaining the transmission support to the frame. * Tighten the horizontal nuts to 50 Nm (37 lb ft). * Tighten the vertical bolts to 100 Nm (74 lb ft). 4. Lower the transmission. 5. Install the nuts to the transmission mount. Refer to Transmission Mount Replacement (2WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair )Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission. 6. Remove the stand or jack. 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Support the lower control arm with a suitable jack. Note: In the following service procedure, it is NOT necessary to separate the brake caliper and mounting bracket. Remove them as an assembly. Support the assembly with mechanics wire or equivalent. 4. Remove the brake caliper assembly and relocate to the side. Refer to Brake Caliper Bracket Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement). Note: Perform the following service procedure if the vehicle is equipped with 4WD. If the vehicle does not have 4WD, proceed to Step 6. 5. Separate the front wheel drive shaft from the steering knuckle. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 6. Remove the speed senor wiring harness from the retaining clips on the upper control arm and frame. 7. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 8. Separate the upper ball joint from the knuckle. Refer to Upper Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Ball Joint/Service and Repair/Front Suspension/Upper Control Arm Ball Joint Replacement)Upper Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Ball Joint/Service and Repair/Upper Control Arm Ball Joint Replacement). 9. Separate the lower ball joint from the knuckle. Refer to Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Ball Joint/Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Ball Joint/Service and Repair/Front Suspension/Lower Control Arm Ball Joint Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 8163 Note: Remove the wheel hub and bearing assembly and knuckle as a unit. 10. Remove the knuckle from the upper and lower control arms. 11. Remove the wheel hub and bearing assembly from the knuckle. Refer to Front Wheel Bearing and Hub Replacement (See: Wheel Bearing/Service and Repair). Installation Procedure 1. Install the wheel hub and bearing assembly onto the knuckle. Refer to Front Wheel Bearing and Hub Replacement (See: Wheel Bearing/Service and Repair). 2. Install the lower control arm/ball joint into the knuckle. Refer to Lower Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Ball Joint/Service and Repair/Lower Control Arm Ball Joint Replacement)Lower Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Ball Joint/Service and Repair/Front Suspension/Lower Control Arm Ball Joint Replacement). Note: The following service procedure is for vehicles equipped with 4WD only. If the vehicle is not equipped with 4WD, proceed to Step 4. 3. Install the wheel drive shaft into the knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 8164 4. Install the upper control arm/ball joint into the knuckle. Refer to Upper Control Arm Ball Joint Replacement (2WD, Z85, ZQ8) (See: Ball Joint/Service and Repair/Front Suspension/Upper Control Arm Ball Joint Replacement)Upper Control Arm Ball Joint Replacement (4WD, 2WD, Z71) (See: Ball Joint/Service and Repair/Upper Control Arm Ball Joint Replacement). 5. Install the outer tie rod end into the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 6. Install the speed senor wiring harness in the retaining clips on the upper control arm and frame. 7. Install the brake caliper mounting bracket. Refer to Brake Caliper Bracket Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Bracket Replacement). 8. Install the wheel drive shaft retaining nut to specifications. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 9. Remove the support from the lower control arm. 10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) 11. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8171 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8172 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8173 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8174 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8175 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 8176 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension Stabilizer Bushing: Service and Repair Front Suspension Stabilizer Shaft Insulator Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 8182 Stabilizer Bushing: Service and Repair Rear Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle at curb height. 3. Remove the stabilizer shaft insulator bracket mounting bolts. 4. Remove the stabilizer shaft insulator brackets. 5. Remove the stabilizer shaft insulators. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 8183 1. Install the stabilizer shaft insulators to the stabilizer shaft. 2. Install the stabilizer shaft insulator brackets to the rear axle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the stabilizer shaft bracket mounting bolts and tighten to 50 Nm (37 lb ft). 4. Remove the rear axle support. 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension Stabilizer Link: Service and Repair Front Suspension Stabilizer Shaft Link Replacement (ZQ8, Z85) Stabilizer Shaft Link Replacement (ZQ8, Z85) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Using the proper size wrench, hold the link ball stud while removing the link nut. 4. Remove the retaining nut from the stabilizer shaft and the lower control arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 8188 5. Remove the stabilizer link from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 8189 1. Install the stabilizer shaft link on the lower control arm and stabilizer shaft. 2. Hand tighten the stabilizer shaft link nuts Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 8190 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Using the proper size wrench to hold the link ball joint, tighten the link nut to 44 Nm (32 lb ft). 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) 5. Remove the support and lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). Stabilizer Shaft Link Replacement (Z71) Stabilizer Shaft Link Replacement (Z71) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the link nut (1) at the lower control arm. 4. Using the proper size wrench to hold the link ball stud, remove the link nut (2) at the stabilizer shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 8191 5. Remove the stabilizer shaft link from the lower control arm and stabilizer shaft. Installation Procedure 1. Install the stabilizer shaft link into the lower control arm and the stabilizer shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 8192 2. Hand tighten the lower link nut (1) at the lower control arm. 3. Hand tighten the link nut at the stabilizer shaft (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Using the proper size wrench to hold the link ball stud, tighten the link nut to 44 Nm (32 lb ft). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) 6. Remove the support and lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 8193 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle at ride height. Note: Do not attempt to hold the stabilizer shaft link near the boot. Use the hex feature on the end of the stud. Failure to do so could damage the boot. 3. Remove the stabilizer shaft link upper nut. 4. Remove the stabilizer shaft link lower nut. 5. Remove the stabilizer shaft link. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 8194 Note: Do not attempt to hold the stabilizer shaft link near the boot. Use the hex feature on the end of the stud. Failure to do so could damage the boot. 1. Install the stabilizer shaft link. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the stabilizer shaft link mounting nuts. * Tighten the stabilizer bar link lower mounting nut to 44 Nm (32 lb ft). * Tighten the stabilizer bar link upper mounting nut to 44 Nm (32 lb ft). 3. Remove the axle support. 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair > Spring Shackle Replacement Shackle: Service and Repair Spring Shackle Replacement Spring Shackle Replacement Special Tools J 36660-A Angle Meter Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle at ride height. 3. Remove the shackle nut and the bolt from the frame. 4. Remove the shackle nut and the bolt from the spring. 5. Remove the shackle assembly from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair > Spring Shackle Replacement > Page 8200 1. Install the shackle assembly to the spring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the shackle nut and bolt to the spring and tighten to 85 Nm (63 lb ft). 3. Install the shackle nut and bolt to the frame and tighten to 85 Nm (63 lb ft). 4. Remove the rear axle support. 5. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair > Spring Shackle Replacement > Page 8201 Shackle: Service and Repair Rear Spring Shackle Bushing Replacement Rear Spring Shackle Bushing Replacement Tools Required J 21474-01 Control Arm Bushing Service Kit Removal Procedure 1. Remove the spring shackle. Refer to Spring Shackle Replacement (See: Spring Shackle Replacement). 2. Remove the spare tire when servicing the left side bushing. 3. Use a blunt punch to straighten out the bushing flange that comes through the inner frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair > Spring Shackle Replacement > Page 8202 4. Remove the spring shackle bushing using J 21474-01 . Installation Procedure 1. Install the new spring shackle bushing using J 21474-01 . 2. Pull the spring shackle bushing into the frame rail until the flanged portion of the spring shackle bushing is flush with the rail. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair > Spring Shackle Replacement > Page 8203 3. Use a blunt punch to stake or flare the spring shackle bushing inner flange. 4. Install the spare tire when servicing the left side bushing. 5. Install the spring shackle. Refer to Spring Shackle Replacement (See: Spring Shackle Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 8208 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Shock Absorber Replacement Shock Absorber Replacement (2WD, Z85, ZQ8) Special Tools J 45400 Strut Spring Compressor Removal Procedure Caution: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8211 1. Remove the absorber/spring assembly upper mounting nuts. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 4. Remove the absorber/spring assembly bolt and nut. 5. Remove the front stabilizer link. Refer to Stabilizer Shaft Link Replacement (ZQ8, Z85) (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85))Stabilizer Shaft Link Replacement (Z71) (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8212 6. Remove the absorber/spring assembly from the vehicle. Caution: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 7. Install the absorber/spring assembly (2) into the J 45400 (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8213 Note: The spring is compressed when the shock absorber moves freely. 8. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed. 9. Remove the absorber upper retaining nut, bushings, and washers. 10. Remove the absorber from the assembly. 11. Do not remove the spring from the J 45400 . Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8214 1. Install the absorber to the J 45400 (1). 2. Install the absorber bushings and washers (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Ensure that the absorber bushings and tennon align correctly with the mounting bracket before securing the retaining nut. 3. Install the absorber retaining nut and tighten to 20 Nm (15 lb ft). 4. Remove the absorber/spring assembly (2) from the J 45400 (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8215 5. Install the absorber/spring assembly to the vehicle. 6. Install the absorber/spring assembly bolt and nut and tighten to 110 Nm (81 lb ft). 7. Install the front stabilizer link. Refer to Stabilizer Shaft Link Replacement (ZQ8, Z85) (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (ZQ8, Z85))Stabilizer Shaft Link Replacement (Z71) (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension/Stabilizer Shaft Link Replacement (Z71)). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 9. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8216 10. Install the absorber/spring assembly upper mounting nuts and tighten to 27 Nm (20 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8217 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure Caution: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle at ride height. 3. Remove the upper absorber bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8218 4. Remove the lower absorber nut and the bolt. 5. Remove the absorber. Installation Procedure 1. Install the absorber. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper absorber bolts and tighten to 35 Nm (26 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8219 3. Install the lower absorber bolt and nut and tighten the nut to 95 Nm (70 lb ft). 4. Remove the rear axle support. 5. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 8220 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension Suspension Travel Bumper: Service and Repair Front Suspension Spring Bumper Replacement (Z71) Spring Bumper Replacement (4WD, 2WD Z71) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the jounce bumper. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 8225 1. Install the jounce bumper. 2. Lower the vehicle. Spring Bumper Replacement (Z85, ZQ8) Spring Bumper Replacement (2WD, Z85, ZQ8) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the jounce bumper mounting bolts. 3. Remove the jounce bumper. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 8226 1. Install the jounce bumper. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the jounce bumper bolts and tighten to 32 Nm (24 lb ft). 3. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 8227 Suspension Travel Bumper: Service and Repair Rear Suspension Spring Jounce Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the auxiliary jounce bumper mounting bolts. 2WD base and RPO ZQ8 suspension. 3. Remove the jounce bumper mounting bolts. 2WD base suspension. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 8228 4. Remove the jounce bumper mounting bolts. 4WD base suspension. 5. Remove the jounce bumper mounting bolts. 2WD RPO ZQ8 suspension. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 8229 6. Remove the jounce bumper mounting bolts. RPO Z71 suspension. 7. Remove the jounce bumper. Installation Procedure 1. Install the jounce bumper. 2. Install the jounce bumper mounting bolts. RPO Z71 suspension. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 8230 3. Install the jounce bumper mounting bolts. 2WD RPO ZQ8 suspension. 4. Install the jounce bumper mounting bolts. 4WD base suspension. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 8231 5. Install the jounce bumper mounting bolts. 2WD base suspension. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the auxiliary jounce bumper mounting bolts. 2WD base and RPO ZQ8 suspension. Tighten the bolts to 50 Nm (37 lb ft). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement Torsion Bar: Service and Repair Torsion Bar Replacement Torsion Bar Replacement Removal Procedure Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Allow the front suspension to hang in the rebound position. 3. Mark the adjuster bolt. Note: To aid in re-assembly record the number of turns that are required to remove the adjuster bolt. 4. Remove the adjuster bolt, spacer and adjuster nut. Note: Take note that the torsion bars are specific to the left and right sides of the vehicle. 5. Remove the adjustment arms and torsion bars as a unit, moving it rearward to disengage the lower control arm. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 8236 1. Install the adjustment arms and torsion bars in relation to where the bars were removed. 2. Install the adjustment arm to the torsion bar and slide the torsion bar forward until the torsion bar fully engages the lower control arm. 3. Install the adjuster bolt, spacer and adjuster nut. 4. Lower the vehicle. 5. Check the Z-Height. Refer to Trim Height Specifications (See: Specifications/Trim Height Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 8237 Torsion Bar: Service and Repair Torsion Bar Anchor Replacement Torsion Bar Anchor Replacement Removal Procedure 1. Remove the torsion bar. Refer to Torsion Bar Replacement (See: Torsion Bar Replacement). 2. Remove the nuts and the bolts from the lower control arm. 3. Remove the torsion bar anchor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 8238 1. Install the torsion bar anchor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nuts and the bolts to the lower control arm and tighten to 80 Nm (59 lb ft). 3. Install the torsion bar. Refer to Torsion Bar Replacement (See: Torsion Bar Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8242 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning ). Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/ABS Component Handling Warning). 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8243 4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled in any of the suspension components. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8244 6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly. 7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8245 Note: Perform the following service procedure with the brake rotor on a flat surface. 8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor. Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor is removed. 9. Remove the wheel bearing/hub from the brake rotor. 10. Clean the contact area between the wheel bearing/hub and the brake rotor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8246 1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from the wheel bearing/hub assembly to the brake rotor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The following service procedure is to be performed on a flat surface and to ensure that the brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT use air tools of any type for this procedure. 3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install the backing plate to the wheel bearing/hub, brake rotor assembly. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8247 6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle. Note: When performing the following service procedure, DO NOT use air tools of any type to torque the brake rotor to hub bolts. 7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8248 8. Install the brake caliper mounting bracket to the steering knuckle. 9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 8249 10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake caliper mounting bracket. Note: The following service procedure is to ensure that the brake rotor is seated properly on the wheel bearing/hub assembly. 11. Tighten the mounting bolts for the brake rotor in sequence. 12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). 14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications (See: Brakes and Traction Control/Disc Brake System/Specifications/Disc Brake Component Specifications). 15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Shaft Nut .................................................................................................................................... .................................................... 260 Nm (191 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 8258 * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8273 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8274 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8275 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8276 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8277 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8280 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the body control module (BCM) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8281 Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement Tire Valve Stem Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8282 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8288 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8289 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8290 Customer TPMS Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8291 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8292 Frequently Asked Questions Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8305 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8306 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8307 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8308 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8309 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8312 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the body control module (BCM) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8313 Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement Tire Valve Stem Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 8314 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Spare Tire Carrier Replacement Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and use the ignition key to remove the lock. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 2. Turn the hoist shaft counterclockwise to lower the spare tire to the ground. Continue to turn the hoist shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by turning the hoist shaft clockwise until you hear two clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by turning the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, turn the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, turn the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is not visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 8319 6. Remove the spare tire hoist guide mounting bolt from the crossmember. 7. Remove the spare tire hoist shaft guide. 8. Remove the bolt. 9. Remove the hoist from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 8320 1. Install the hoist. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt and tighten to 40 Nm (30 lb ft). 3. Install the spare tire hoist shaft guide. 4. Install the mounting bolt for the guide and tighten to 30 Nm (20 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 8321 5. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 6. Turn the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8330 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8331 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8332 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 8337 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 8342 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 8343 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 8344 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8350 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8351 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8352 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 8357 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8362 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8363 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8368 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8369 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8370 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 8375 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 8380 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 8381 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 8382 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8388 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8389 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8390 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 8395 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8400 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8401 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8402 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Inflate the tire to the manufacturer specified pressure as stated on the tire. 4. Submerge the tire/wheel into a water bath in order to locate the leak. 5. Inscribe a mark on the wheel in order to indicate the leak areas. 6. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 7. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Important: Do not damage the exterior surface of the wheel. 8. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 9. Use general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area. 10. Apply 3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 1052366 or equivalent, to the leak area. 11. Allow for the adhesive/sealant to dry. 12. Align the inscribed mark on the tire with the valve stem on the wheel. 13. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 14. Inflate the tire to the manufacturer specified pressure as stated on the tire. 15. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 16. Balance the tire and wheel. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). 17. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 18. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 8405 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Note: * If the wheels are chrome-plated, do not re-plate or refinish the wheels. * If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: * Corrosion * Scrapes * Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Warning To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: * Lubricants * Wax * Dirt Note: * Do not re-machine the wheel. * Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Note: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Note: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: * Corrosion * Overspray * Dirt 13. Install the tire and wheel assembly to the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8409 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning ). Warning: Refer to ABS Component Handling Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/ABS Component Handling Warning). 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the front brake caliper. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 3. Remove the speed sensor electrical connector and the mounting bracket. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8410 4. To ensure the ease of removal, bundle speed sensor wiring harness so not to have it entangled in any of the suspension components. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering/Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8411 6. Remove the mounting bolts for the wheel bearing/hub, brake rotor assembly. 7. Remove the wheel bearing/hub, brake rotor assembly from the steering knuckle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8412 Note: Perform the following service procedure with the brake rotor on a flat surface. 8. Remove the mounting bolt from the wheel bearing/hub, to the brake rotor. Note: The splash shield will come off the steering knuckle when the wheel bearing/hub, brake rotor is removed. 9. Remove the wheel bearing/hub from the brake rotor. 10. Clean the contact area between the wheel bearing/hub and the brake rotor. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8413 1. Position the wheel bearing/hub assembly on the brake rotor. 2. Install the mounting bolts from the wheel bearing/hub assembly to the brake rotor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The following service procedure is to be performed on a flat surface and to ensure that the brake rotor is securely attached to the hub assembly prior to the final torquing procedure. DO NOT use air tools of any type for this procedure. 3. Tighten the bolts in crisscross pattern. Tighten the mounting bolts to 20 Nm (15 lb ft). 4. Install the backing plate to the wheel bearing/hub, brake rotor assembly. Note: The following service procedure applies to those vehicles that are equipped with 4 wheel drive ONLY. 5. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement (See: Steering/Front Steering Knuckle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8414 6. Install the wheel bearing/hub, brake rotor assembly in the steering knuckle. Note: When performing the following service procedure, DO NOT use air tools of any type to torque the brake rotor to hub bolts. 7. Install the wheel bearing/hub, brake rotor mounting bolts and tighten to 125 Nm (92 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8415 8. Install the brake caliper mounting bracket to the steering knuckle. 9. Install the mounting bolts for the brake caliper mounting bracket and tighten to 175 Nm (129 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 8416 10. Position a large screwdriver or pry bar in the cooling fins of the brake rotor and the brake caliper mounting bracket. Note: The following service procedure is to ensure that the brake rotor is seated properly on the wheel bearing/hub assembly. 11. Tighten the mounting bolts for the brake rotor in sequence. 12. Using a torque wrench, tighten the mounting bolts to 110 Nm (81 lb ft). 13. Install the speed sensor mounting bracket and re-connect the electrical connector. Refer to Front Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor Replacement). 14. Check for hub/rotor/bearing LRO specifications. Refer to Disc Brake Component Specifications (See: Brakes and Traction Control/Disc Brake System/Specifications/Disc Brake Component Specifications). 15. Install the brake caliper assembly. Refer to Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Brake Caliper Replacement). 16. Install the wheel speed sensor to the body. 17. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Shaft Nut .................................................................................................................................... .................................................... 260 Nm (191 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts........................................................................................................................................... .......................................................140 Nm (103 lb ft) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 8424 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Replacement). 4. Remove the wheel stud from the hub flange using the J 43631 . 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 8427 7. Install the brake rotor. Refer to Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Replacement). 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 8428 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 3. Using the J 43631 , remove the wheel stud. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 8429 1. Position the wheel stud in the axle flange. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 6. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Instrument Panel/Center Console Component Views Air Door Actuator / Motor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the I/P Components 1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 8436 Air Door Actuator / Motor: Locations Harness Routing Views Harness Routing Views HVAC Harness Routing 1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 8437 Air Door Actuator / Motor: Diagrams Component Connector End Views Recirculation Actuator (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Control Cam Replacement Air Door Actuator / Motor: Service and Repair Mode Control Cam Replacement Mode Control Cam Replacement Removal Procedure Note: The mode cam can be accessed from the driver side floor near the accelerator peddle. 1. Remove the mode control cable (4) from the retaining clip (3). 2. Remove the mode control cable (4) from the mode cam (2). 3. Remove the screw (1) from the mode cam. 4. Remove the mode cam. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Control Cam Replacement > Page 8440 1. Install the mode cable (4). 2. Make certain that the cable is properly seated in the notch in the HVAC module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the mode cam screw. Tighten the screw to 2 Nm (18 lb in). 4. Install the mode control cable (4) to the mode cam (2). 5. Install the mode control cable (4) to the retaining clip (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Control Cam Replacement > Page 8441 Air Door Actuator / Motor: Service and Repair Recirculation Actuator Replacement Recirculation Actuator Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair). 2. Remove the recirculation actuator screws. 3. Remove the electrical connector (3) from the recirculation actuator (2). 4. Remove the recirculation actuator. Installation Procedure 1. Install the recirculation actuator (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Control Cam Replacement > Page 8442 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws to the recirculation actuator. Tighten the screws to 1.9 Nm (17 lb ft). 3. Connect the electrical connector (3) to the recirculation actuator (2). 4. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement Air Door Cable: Service and Repair Mode Control Cable Replacement Mode Control Cable Replacement Removal Procedure 1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 2. Remove the mounting screws from the HVAC control assembly. 3. Remove the mode cable (4) from the retaining clip (3) and remove the mode cable. 4. Remove the mode cable (4) from the mode control cam. 5. Remove the mode cable (3) from the HVAC control assembly (6). 6. Remove the mode control cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8447 Installation Procedure 1. Install the mode cable (3). Make certain that the cable is properly seated in the notches in the HVAC control assembly (6). 2. Install the mode cable (3) to the HVAC control assembly (6). 3. Install the mode cable to the retaining clip. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the mounting screws to the HVAC control assembly. Tighten the screws to 1.9 Nm (17 lb in). 5. Install the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 6. Install the mode cable (4) to the mode control cam (2). 7. Install the mode cable (4) to the retaining clip (3). 8. Install the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8448 and Repair/Radio Replacement). 9. Install the HVAC control assembly. Refer to Heater and Air Conditioning Control Replacement (See: Control Assembly/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8449 Air Door Cable: Service and Repair Temperature Control Cable Replacement Temperature Control Cable Replacement Removal Procedure 1. Remove the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the mounting screws from the HVAC control assembly. 3. Remove the temperature cable (4) from the retaining clip and remove the temperature cable. 4. Remove the temperature cable (4) from the temperature control cam (5). 5. Fully open the I/P storage compartment. 6. Remove the temperature control cable from the retaining clip. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 8450 7. Remove the temperature control cable (9) from the temperature actuator cam (10). 8. Remove the temperature control cable. Installation Procedure 1. Install the temperature cable (4). 2. Install the temperature control cable (9) to the temperature actuator cam (10). 3. Install the temperature cable to the retaining clip. 4. Install the temperature cable (4) to the temperature control cam (5). 5. Install the temperature cable (4) to the retaining clip. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the mounting screws to the HVAC control assembly. Tighten the screws to 1.9 Nm (17 lb in). 7. Install the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair Air Duct: Service and Repair Air Distributor Duct Replacement Removal Procedure 1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the air distributor duct (1) from the instrument panel. Installation Procedure 1. Install the air distributor duct (1) to the instrument panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the retaining screws to the air distributor duct. Tighten the screws to 1.9 Nm (17 lb in). 3. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement Air Register: Service and Repair Rear Floor Air Outlet Replacement Rear Floor Air Outlet Replacement Removal Procedure 1. Remove the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). 2. Roll the carpeting back to expose the rear floor air ducts. 3. Remove the rear floor ducts from the floor studs. 4. Remove the rear floor duct. Installation Procedure 1. Install the rear floor air duct. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8458 2. Install the rear floor ducts from the floor studs. 3. Position the carpeting back into place. 4. Install the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8459 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side Instrument Panel Outer Air Outlet Replacement - Left Side Removal Procedure 1. Using a flat-bladed plastic tool, carefully release the 4 tabs (1) retaining the air outlet assembly to the instrument panel (I/P). 2. Remove the air outlet assembly from the I/P Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8460 3. If replacing the vent assembly or the bezel, separate the bezel from the vent assembly by carefully releasing the 4 retaining tabs. Installation Procedure 1. If replacing the vent assembly or the bezel, install the bezel to the vent assembly by seating the 4 retaining tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8461 2. Install the air outlet assembly to the I/P ensuring the retaining tabs are fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8462 Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement Instrument Panel Center Air Outlet Replacement Removal Procedure 1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the right air outlet assembly from the trim plate. 3. Remove the left air outlet assembly from the trim plate. Installation Procedure 1. Install the left air outlet assembly to the trim plate. 2. Install the right air outlet assembly to the trim plate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8463 3. Install the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8464 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Right Side Instrument Panel Outer Air Outlet Replacement - Right Side Removal Procedure 1. Using a flat-bladed plastic tool, carefully release the 4 tabs (1) retaining the air outlet assembly to the instrument panel (I/P). 2. Remove the air outlet assembly from the I/P Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8465 3. If replacing the vent assembly or the bezel, separate the bezel from the vent assembly by carefully releasing the 4 retaining tabs. Installation Procedure 1. If replacing the vent assembly or the bezel, install the bezel to the vent assembly by seating the 4 retaining tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Rear Floor Air Outlet Replacement > Page 8466 2. Install the air outlet assembly to the I/P ensuring the retaining tabs are fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor Clicking/Chirping/Whirring Noises Blower Motor: Customer Interest A/C - Blower Motor Clicking/Chirping/Whirring Noises TECHNICAL Bulletin No.: 06-01-38-001C Date: July 14, 2010 Subject: Excessive Blower Motor Clicking/Chirping/Whirring or Ticking Noise on Low Speed (Install Blower Motor Sound Insulator Cover) Models: 2005-2010 Chevrolet Colorado 2005-2010 GMC Canyon Supercede: This bulletin is being revised to update the model years to 2010. Please discard Corporate Bulletin Number 06-01-38-001B (Section 01 - HVAC). Condition Some customers may comment on excessive or annoying blower motor noise on low fan speed. Sounds may include ticking, chirping, clicking or whirring noises. Cause The blower motor is located within the vehicle under the passenger side lower IP. This location, while allowing for increased serviceability, does not offer much isolation from blower motor noise. Correction To reduce the noise level from the blower motor, install a blower motor sound insulator cover using the procedure below. 1. Remove the front passenger door sill molding. 2. Remove the front passenger side interior kick panel molding. 3. Remove the front passenger interior floor courtesy light. 4. Remove the BCM connector facing the blower motor. 5. Remove the wire retaining metal clip from the BCM harness. 6. Install the molded insulator to the blower motor. Refer to the above illustration. The insulator may need to be flexed in order to be properly situated on the motor. When the insulator is properly installed, it will be form fitted to the motor and the retainer hole in the cover (1) will align with a hole in the back side of the motor body. 7. A stud will align with the second hole in the insulating cover. Refer to location (2) in the above illustration, which shows the location of the stud (not visible in photo). Please note the location of the BCM in the photo. This should aid in properly locating the cover. 8. Use the push-pin to secure the cover in place. 9. Re-route the BCM harness over the newly installed cover and retain using the metal clip. This should give additional support to the flexible blower motor cover. 10. Install the front passenger interior floor courtesy light. 11. Install the front passenger side interior kick panel molding. 12. Install the front passenger door sill molding. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor Clicking/Chirping/Whirring Noises > Page 8475 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor Clicking/Chirping/Whirring Noises Blower Motor: All Technical Service Bulletins A/C - Blower Motor Clicking/Chirping/Whirring Noises TECHNICAL Bulletin No.: 06-01-38-001C Date: July 14, 2010 Subject: Excessive Blower Motor Clicking/Chirping/Whirring or Ticking Noise on Low Speed (Install Blower Motor Sound Insulator Cover) Models: 2005-2010 Chevrolet Colorado 2005-2010 GMC Canyon Supercede: This bulletin is being revised to update the model years to 2010. Please discard Corporate Bulletin Number 06-01-38-001B (Section 01 - HVAC). Condition Some customers may comment on excessive or annoying blower motor noise on low fan speed. Sounds may include ticking, chirping, clicking or whirring noises. Cause The blower motor is located within the vehicle under the passenger side lower IP. This location, while allowing for increased serviceability, does not offer much isolation from blower motor noise. Correction To reduce the noise level from the blower motor, install a blower motor sound insulator cover using the procedure below. 1. Remove the front passenger door sill molding. 2. Remove the front passenger side interior kick panel molding. 3. Remove the front passenger interior floor courtesy light. 4. Remove the BCM connector facing the blower motor. 5. Remove the wire retaining metal clip from the BCM harness. 6. Install the molded insulator to the blower motor. Refer to the above illustration. The insulator may need to be flexed in order to be properly situated on the motor. When the insulator is properly installed, it will be form fitted to the motor and the retainer hole in the cover (1) will align with a hole in the back side of the motor body. 7. A stud will align with the second hole in the insulating cover. Refer to location (2) in the above illustration, which shows the location of the stud (not visible in photo). Please note the location of the BCM in the photo. This should aid in properly locating the cover. 8. Use the push-pin to secure the cover in place. 9. Re-route the BCM harness over the newly installed cover and retain using the metal clip. This should give additional support to the flexible blower motor cover. 10. Install the front passenger interior floor courtesy light. 11. Install the front passenger side interior kick panel molding. 12. Install the front passenger door sill molding. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 06-01-38-001C > Jul > 10 > A/C - Blower Motor Clicking/Chirping/Whirring Noises > Page 8481 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Instrument Panel/Center Console Component Views Blower Motor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the I/P Components 1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 8484 Blower Motor: Locations Harness Routing Views Harness Routing Views HVAC Harness Routing 1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 Blower Motor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8545 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8546 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8547 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8548 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8549 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8550 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8551 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8552 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8553 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8554 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8559 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8580 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8581 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8582 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8583 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8584 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8585 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8586 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8588 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8589 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8592 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8593 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8594 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8595 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8596 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8597 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8598 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8599 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8602 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8603 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8604 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8605 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8606 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8607 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8608 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8609 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8610 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8611 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8612 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8613 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8639 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8648 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8649 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8650 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8651 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8652 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8653 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8654 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8655 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8656 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8657 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 Blower Motor: Connector Views Component Connector End Views Blower Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8659 Blower Motor: Service and Repair Blower Motor Replacement Removal Procedure 1. Remove the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 2. Remove the blower motor mounting screws. 3. Remove the blower motor cooling tube (2). 4. Disconnect the blower motor electrical connector (4). 5. Remove the blower motor (3). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8660 1. Install the blower motor (3). 2. Connect the blower motor electrical connector (4). 3. Install the blower motor cooling tube (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the blower motor mounting screws. Tighten the screws to 2 Nm (18 lb in). 5. Install the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Instrument Panel/Center Console Component Views Blower Motor Resistor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the I/P Components 1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 8665 Blower Motor Resistor: Locations Harness Routing Views Harness Routing Views HVAC Harness Routing 1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8666 Blower Motor Resistor: Diagrams Component Connector End Views Blower Motor Resistor Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8667 Blower Motor Resistor: Service and Repair Blower Motor Resistor Assembly Replacement Removal Procedure 1. Disconnect the blower motor resistor electrical connector (1). 2. Remove the blower motor resistor mounting screws. 3. Remove the blower motor resistor (2). Installation Procedure 1. Install the blower motor resistor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8668 2. Install the blower motor resistor mounting screws. Tighten the screws to 1.9 Nm (17 lb in). 3. Connect the blower motor resistor electrical connector (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams Compressor Clutch: Diagrams Component Connector End Views A/C Compressor Clutch (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8682 Compressor Clutch Relay: Service and Repair Compressor Relay Replacement Removal Procedure 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). Installation Procedure 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair Air Conditioning Condenser Replacement Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Remove the radiator. Refer to Radiator Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair). 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 3. Remove the receiver dryer. 4. Remove the condenser inlet hose bolt. 5. Remove the condenser inlet hose. 6. Remove the condenser outlet hose bolt. 7. Remove the condenser outlet hose. 8. Remove the condenser from mounts on the radiator (1). 9. Remove the condenser. Installation Procedure Note: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities (See: Specifications/Capacity Specifications) for the capacity information. 1. Install the condenser to the radiator. 2. If replacing the condenser, transfer the components from the old condenser as necessary. 3. Install the condenser to the mounts on the radiator (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the condenser retaining bolts to the radiator. Tighten the bolts to 28 Nm (21 lb ft). 5. Install the receiver dyer. 6. Install the condenser inlet hose. 7. Install the condenser inlet hose bolt. Tighten the bolts to 20 Nm (15 lb ft). 8. Install the condenser outlet hose. 9. Install the condenser outlet hose bolt. Tighten the bolts to 20 Nm (15 lb ft). 10. Install the radiator. Refer to Radiator Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 8686 11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 12. Leak test the fittings of the components using the J 39400-A . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Harness Routing Views Control Assembly: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Harness Routing Views > Page 8691 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Harness Routing Views > Page 8692 Control Assembly: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8693 Control Assembly: Diagrams Component Connector End Views HVAC Control Module X1 HVAC Control Module X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8694 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8695 Control Assembly: Service and Repair Heater and Air Conditioning Control Replacement Removal Procedure 1. Remove the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the screws (7,2) from the HVAC control assembly. 3. Remove the HVAC control assembly from the instrument panel. 4. Disconnect the mode cable from the HVAC control assembly. Refer to Mode Control Cable Replacement (See: Air Door/Air Door Cable/Service and Repair/Mode Control Cable Replacement). 5. Disconnect the temperature cable from the HVAC control assembly. Refer to Temperature Control Cable Replacement (See: Air Door/Air Door Cable/Service and Repair/Temperature Control Cable Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8696 6. Disconnect the HVAC control assembly electrical connectors. 7. Remove the HVAC control assembly. Installation Procedure 1. Install the HVAC control assembly. 2. Connect the HVAC control assembly electrical connectors. Note: Do not bend the mode and temperature cables. 3. Connect the mode cable to the HVAC control assembly. Refer to Mode Control Cable Replacement (See: Air Door/Air Door Cable/Service and Repair/Mode Control Cable Replacement). 4. Connect the temperature cable to the HVAC control assembly. Refer to Temperature Control Cable Replacement (See: Air Door/Air Door Cable/Service and Repair/Temperature Control Cable Replacement). 5. Install the HVAC control assembly to the instrument panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8697 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the HVAC control assembly screws. Tighten the screws to 1.9 Nm (18 lb in). 7. Install the accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Sealing Washer Replacement A/C Coupler O-ring: Service and Repair Sealing Washer Replacement Sealing Washer Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Important: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Sealing Washer Replacement > Page 8703 A/C Coupler O-ring: Service and Repair O-Ring Replacement O-Ring Replacement Removal Procedure 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure * For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). * For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. Installation Procedure 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Important: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Sealing Washer Replacement > Page 8704 7. Assemble the A/C components. Refer to the appropriate repair procedure. * For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. * For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations Evaporator Case: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8716 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8717 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8723 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8724 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 8725 Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair). 2. Remove the screws to separate the HVAC module assembly halves. 3. Remove the evaporator temperature sensor control module screw. 4. Reposition the evaporator temperature sensor control module. 5. Separate the HVAC module assembly (1, 4). 6. Remove the evaporator temperature sensor from the evaporator. 7. Remove the evaporator core (1) from the HVAC module assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 8726 Installation Procedure Note: If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Capacities (See: Specifications/Capacity Specifications) for system capacity information. 1. Install the seal between the HVAC module assembly halves. 2. Install the evaporator core (1) to the HVAC module assembly. 3. Install the evaporator temperature sensor to the evaporator core. 4. Assemble the HVAC module assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the screws to join the HVAC module assembly halves. Tighten the screws to 1.9 Nm (17 lb in). 6. Install the evaporator temperature sensor control module screw. Tighten the to 1.9 Nm (17 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 8727 7. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair Evaporator Drain Tube: Service and Repair Evaporator Tube Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Harness Routing Views Evaporator Temperature Sensor / Switch: Locations Harness Routing Views Harness Routing Views HVAC Harness Routing 1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Harness Routing Views > Page 8735 Evaporator Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the I/P Components 1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8736 Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Evaporator Temperature Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8737 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement Removal Procedure 1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 2. Remove the mounting screw from the evaporator temperature control module. 3. Disconnect the electrical connector from the control module. 4. Cut the evaporator temperature sensor wire near the control module. Note: * Note the mounting position of the evaporative temperature sensor (a, b) and use these measurements upon installation. * If you are replacing only the control module, proceed to Step 4 of the Installation Procedure. 5. Remove the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See: Evaporator Core/Service and Repair). 6. Using needle nose pliers, carefully remove the evaporator temperature sensor from the evaporator core. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8738 1. Install the evaporator temperature sensor to the evaporator core. Place the sensor approximately 3.5 cm (1.4 in) from the side (a) and 5 cm (2 in) from the bottom (b) corner of the evaporator core. Note: Improper wire alignment will pinch and may cut the sensor wires. 2. Align the evaporator temperature sensor wires with the opening in the upper HVAC module case. 3. Install the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See: Evaporator Core/Service and Repair). 4. Cut the evaporator temperature sensor from the replacement assembly. 5. Connect the original sensor wire to the replacement assembly. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Connect the electrical connector to the evaporator temperature control module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the mounting screw to the control module. Tighten the screw to 1.9 Nm (17 lb in). 8. Install the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair Air Conditioning Evaporator Thermal Expansion Valve Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the nut from the TXV mounting stud. 3. Remove the evaporator tube and the compressor suction hose from the TXV. 4. Remove and discard the seal washers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 8742 5. Remove the TXV bolts. 6. Remove the TXV. 7. Remove and discard the seal washers. Installation Procedure 1. Install new seal washers to the evaporator core fittings. Refer to Sealing Washer Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement). 2. Install the TXV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the TXV bolts. Tighten the bolts to 7 Nm (62 lb in). 4. Install new sealing washers on the evaporator tube and the compressor suction hose fittings. Refer to Sealing Washer Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement). 5. Install the evaporator tube and the compressor suction hose to the TXV. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 8743 6. Install the TXV nut. Tighten the nut to 20 Nm (15 lb ft). 7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 8. Leak test the fittings using the J 39400-A . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Heater Core Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair). 2. Remove the heater core pipes clamp screw (3). 3. Remove the heater core pipes clamp (2). 4. Remove the heater core clamp screws. 5. Remove the heater core clamp (2). 6. Remove the heater core from the HVAC module. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 8747 1. Install the heater core to the HVAC module. 2. Install the heater core clamp (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the heater core clamp screws. Tighten the screws to 1.9 Nm (17 lb in). 4. Install the heater core pipes clamp (2). 5. Install the heater core pipes clamp screw (3). Tighten the screw to 20 Nm (15 lb ft). 6. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement Tools Required * J 38185 Hose Clamp Pliers * J 43181 Heater Line Quick Connect Release Tool Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 43181 , release the inlet heater hose quick connect (1) from the heater core inlet. 3. Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Remove the heater inlet hose (3) from the inlet hose fitting (6) at the engine block. 5. Remove the heater inlet hose (3). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8752 1. Apply coolant to the end of the heater inlet hose (5). Important: When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 2. Install the heater inlet hose (3) to the inlet hose fitting (6) at the engine block. 3. Position the inlet heater hose clamp (4) at the engine block using J 38185 . 4. Install the heater inlet hose (3) to the heater core inlet. 5. Press the quick connect (1) onto the heater core inlet until fully seated. 6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8753 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 3. Remove the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 4. Using the J 38185 disconnect the outlet hose from the heater core outlet tube. 5. Remove the heater outlet hose from the heater core. 6. Position the outlet heater hose clamp (6) at the water pump using J 38185 . 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 . 4. Install the heater outlet hose to the heater core. 5. Position the outlet heater hose clamp at the heater core using J 38185 . 6. Install the transmission. Refer to Transmission Replacement (4WD 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (4WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD 5.3L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement)Transmission Replacement (2WD Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8754 2.9L and 3.7L) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 7. Install the generator. Refer to Generator Replacement (LLV/LLR) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement)Generator Replacement (LH8) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 8. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8755 Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8756 Heater Hose: Service and Repair Heater Inlet Pipe Replacement Heater Inlet Pipe Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 38185 , reposition the heater hose outlet clamp from the heater pipe inlet. 3. Remove the heater hose outlet from the heater pipe inlet. 4. Remove the exhaust heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR) (). 5. Remove the heater inlet pipe bolt. 6. Remove the heater inlet pipe. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8757 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3. Install the heater hose outlet to the heater pipe inlet. 4. Using the J 38185 , reposition the heater hose outlet clamp to the heater pipe inlet. 5. Install the exhaust heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LLV) ()Exhaust Manifold Heat Shield Replacement (LLR) (). 6. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8758 Heater Hose: Service and Repair Heater Outlet Pipe Replacement Heater Outlet Pipe Replacement Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 38185 , reposition the heater hose inlet clamp from the heater pipe outlet. 3. Remove the heater hose inlet from the heater pipe outlet. 4. Loosen the heater pipe outlet. 5. Remove the heater pipe outlet. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 8759 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater outlet hose fitting. Tighten the heater outlet hose fitting to 45 Nm (33 lb ft). 3. Install the heater hose inlet to the heater pipe outlet. 4. Using the J 38185 , reposition the heater hose inlet clamp to the heater pipe outlet. 5. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise Under Heavy Load Hose/Line HVAC: Customer Interest A/C - Moan/Whine Noise Under Heavy Load TECHNICAL Bulletin No.: 09-01-38-002 Date: May 14, 2009 Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose With Updated Design) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped with Engine RPO LH8 Condition Some customers may comment on a moan and/or a whine type noise when the A/C compressor is engaged during high system loads. These high load operating conditions include high ambient temperatures, extended periods of idle operation and towing applications. The noise will stop immediately when the compressor is disengaged. Cause This condition may be caused by the factory installed A/C suction hose lacking sufficient noise dampening. Correction Install a new A/C suction hose assembly. This new hose assembly has an improved noise dampening design. Refer to Suction Hose Replacement (LH8) in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-01-38-002 > May > 09 > A/C - Moan/Whine Noise Under Heavy Load Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Whine Noise Under Heavy Load TECHNICAL Bulletin No.: 09-01-38-002 Date: May 14, 2009 Subject: A/C Moan and/or Whine Noise Under Heavy Load Condition (Replace A/C Suction Hose With Updated Design) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3 , H3T, H3G Export All Equipped with Engine RPO LH8 Condition Some customers may comment on a moan and/or a whine type noise when the A/C compressor is engaged during high system loads. These high load operating conditions include high ambient temperatures, extended periods of idle operation and towing applications. The noise will stop immediately when the compressor is disengaged. Cause This condition may be caused by the factory installed A/C suction hose lacking sufficient noise dampening. Correction Install a new A/C suction hose assembly. This new hose assembly has an improved noise dampening design. Refer to Suction Hose Replacement (LH8) in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement Discharge Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 8775 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 8776 Hose/Line HVAC: Service and Repair Suction Screen Replacement Suction Screen Replacement Tools Required J 44551 Suction Screen Kit Removal Procedure Important: Suction screens are intended to be installed in the suction hose after a major compressor failure. 1. Remove the A/C suction hose from the A/C compressor. Refer to Suction Hose Replacement (LH8) (See: Suction Hose Replacement)Suction Hose Replacement (LLV, LLR) (See: Suction Hose Replacement). 2. Using the J-44551-9 Universal Removal Tool, place the tip of the tool under the inside edge of the compression band of the suction screen and the cushioning fulcrum pad against the open end of the hose or manifold fitting. Important: Do not damage the end of the hose or manifold. 3. Pry upward on the band and move the tool around the diameter of the screen as necessary to remove the screen. Installation Procedure 1. Using a caliper that reads to 3 decimal places, measure the ID of the suction hose or manifold suction fitting. To determine the correct size screen for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See: Specifications/Mechanical Specifications/Heating, Ventilation, and Air Conditioning/Compressor Suction Screen and Tool Selection Specifications). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 8777 2. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt: * The brass Universal Mandrel is for use on hose fittings with a smooth bore where the screen installs flush with the end of the fitting. * The 11.96 mm (0.471 in) Mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with an internal hourglass shape where the screen installs at the recessed, reduced diameter point. 3. Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting. 4. Place the suction hose fitting or suction hose side of the manifold into the installation tool fixture J-44551-5 (3) so it is supported by the tools legs. Important: Correct placement of the J-44551-5 is critical. 5. Lubricate the A/C suction screen with the applicable refrigerant oil. 6. Align the screen (2), basket first; into the suction hose bore then hand tighten the bolt until contact is made between the hose, screen and tool. 7. Turn the bolt of the installation tool clockwise pressing the screen into the bore until the mandrel shoulder contacts the end of the hose fitting. 8. Unscrew the bolt and remove the installation tool from the hose or manifold. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 8778 Important: Clean the surface to be used for attaching the label. 9. Install the J-44551-1 Suction Screen Notification Label. 10. Install the A/C hose to the A/C compressor. Refer to Suction Hose Replacement (LH8) (See: Suction Hose Replacement)Suction Hose Replacement (LLV, LLR) (See: Suction Hose Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement Tools Required * J 43181 Heater Line Quick Connect Release Tool * J 39400-A Halogen Leak Detector Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 3. Remove the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 4. Release the heater hose clamps using J 43181 . 5. Disconnect the heater hose quick connects (2) and (3) from the heater core. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 8782 6. Remove the retaining nut from the TXV stud. 7. Remove the evaporator tube and suction hose from the TXV. 8. Remove the radio antenna from the HVAC module. 9. Reposition the carpet. 10. Remove rear floor duct. Refer to Rear Floor Air Outlet Replacement (See: Air Register/Service and Repair/Rear Floor Air Outlet Replacement). 11. Remove the HVAC module retaining nuts from the cowl. 12. Remove the HVAC module assembly. Installation Procedure 1. Install the HVAC module assembly. 2. Install the HVAC module retaining nuts from the cowl. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the HVAC module retaining nuts. Tighten the nut to 4.5 Nm (40 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 8783 4. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module assembly as necessary. 5. Install the HVAC module assembly (8). 6. Install rear floor duct. Refer to Rear Floor Air Outlet Replacement (See: Air Register/Service and Repair/Rear Floor Air Outlet Replacement). 7. Reposition the carpet. 8. Install the radio antenna to the HVAC module. 9. Connect the heater hose quick connects (2) and (3) to the heater core. 10. Install the evaporator tube and suction hose to the TXV. 11. Install the retaining nut to the TXV stud. 12. Tighten the retaining nut. Tighten the nut to 4.5 Nm (40 lb in). 13. Install the I/P carrier. Refer to Instrument Panel Carrier Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 15. Leak test the fittings of the components using the J 39400-A . 16. Refill the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Vac N Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair Receiver and Dehydrator Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). Warning Do not remove hoses or lines before system is fully discharged. System may be under pressure and contact with R134a may cause personal injury. 3. Remove the condenser hose bolt from the receiver dehydrator. 4. Remove the condenser hose from the receiver dehydrator. 5. Remove the evaporator tube bolt from the receiver dehydrator. 6. Remove the evaporator tube from the receiver dehydrator. 7. Install caps on the condenser hose and the evaporator tube assembly to prevent moisture entry and oil spillage. 8. Remove the receiver dehydrator bracket bolts and the receiver dehydrator assembly. 9. Loosen the receiver dehydrator clamp bolt and remove receiver dehydrator. Installation Procedure 1. If replacing the receiver dehydrator add the appropriate amount of PAG oil to the system. Refer to Refrigerant System Capacities (See: Specifications/Capacity Specifications) for capacity information. 2. Install the receiver dehydrator bottle into the clamp but do not tighten. 3. Install new O-rings. Refer to O-Ring Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/O-Ring Replacement). Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the receiver dehydrator bracket bolts. 5. Tighten the receiver/dehydrator clamp bolt. Tighten the bolt to 5 Nm (44 lb in). 6. Remove the condenser hose to condenser cap and plug and install a new seal washer. Refer to Sealing Washer Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement). 7. Install the evaporator tube to the receiver dehydrator. 8. Install the evaporator tube bolt to the receiver dehydrator. Tighten the bolt to 20 Nm (15 lb ft). 9. Install the condenser hose to the receiver dehydrator. 10. Hand start the condenser hose bolt to the receiver dehydrator. Tighten the bolt to 20 Nm (15 lb ft). 11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 12. Using the J 39400-A leak test the fittings of the component. 13. Install the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8791 Refrigerant: Fluid Type Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8796 Refrigerant Oil: Fluid Type Specifications Refrigerant System Capacities Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8801 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8802 Refrigerant Pressure Sensor / Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8803 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8804 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8805 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8806 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8811 Compressor Clutch Relay: Service and Repair Compressor Relay Replacement Removal Procedure 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). Installation Procedure 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Harness Routing Views Evaporator Temperature Sensor / Switch: Locations Harness Routing Views Harness Routing Views HVAC Harness Routing 1 - Evaporator Temperature Sensor (C60) 2 - X203 (I/P Harness to the HVAC Harness) 3 Recirculation Actuator (C60) 4 - Blower Motor 5 - J202 6 - Blower Motor Resistor Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Harness Routing Views > Page 8820 Evaporator Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Behind the I/P Components 1 - HVAC Module Assembly 2 - Evaporator Temperature Sensor (C60) 3 - X203 4 - Recirculation Actuator (C60) 5 - Blower Motor 6 - Blower Motor Resistor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8821 Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Evaporator Temperature Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8822 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement Removal Procedure 1. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 2. Remove the mounting screw from the evaporator temperature control module. 3. Disconnect the electrical connector from the control module. 4. Cut the evaporator temperature sensor wire near the control module. Note: * Note the mounting position of the evaporative temperature sensor (a, b) and use these measurements upon installation. * If you are replacing only the control module, proceed to Step 4 of the Installation Procedure. 5. Remove the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See: Evaporator Core/Service and Repair). 6. Using needle nose pliers, carefully remove the evaporator temperature sensor from the evaporator core. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8823 1. Install the evaporator temperature sensor to the evaporator core. Place the sensor approximately 3.5 cm (1.4 in) from the side (a) and 5 cm (2 in) from the bottom (b) corner of the evaporator core. Note: Improper wire alignment will pinch and may cut the sensor wires. 2. Align the evaporator temperature sensor wires with the opening in the upper HVAC module case. 3. Install the evaporator core. Refer to Air Conditioning Evaporator Core Replacement (See: Evaporator Core/Service and Repair). 4. Cut the evaporator temperature sensor from the replacement assembly. 5. Connect the original sensor wire to the replacement assembly. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Connect the electrical connector to the evaporator temperature control module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the mounting screw to the control module. Tighten the screw to 1.9 Nm (17 lb in). 8. Install the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8828 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8829 Refrigerant Pressure Sensor / Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8830 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 8831 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8832 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8833 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LH8) (5.3L) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts Repairs and Inspections Required After a Collision: Service and Repair Seat Belts Repairs and Inspections Required After a Collision Warning Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: * Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. * Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. * Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. * Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 8842 Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable Restraints Repairs and Inspections Required After a Collision Accident With or Without Inflator Module Deployment - Component Inspections Warning Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. * The steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection (See: Steering and Suspension/Steering/Steering Column/Testing and Inspection/Initial Inspection and Diagnostic Overview/Steering Column Accident Damage Inspection). * The instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. * The I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. * The seat belts-Perform the seat belt operational and functional checks. * The I/P mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of damage. * The roof rail and roof rail module mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * Passenger seat bottom equipped with Passenger Presence System (PPS)-Check for any DTCs or problems that may cause the PPS not to function properly. Accident With Frontal Air Bag Deployment - Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Note: The front passenger seat is equipped with a PPS, which detects an occupant. If the requirements for disabling the I/P air bag are met then the PPS will communicate with the SDM to disable/turn off the I/P air bag, even in a accident. For more information on the PPS refer to SIR System Description and Operation (See: Air Bag Systems/Description and Operation). * Inflatable restraint front end sensors * Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed above * Inflatable restraint sensing and diagnostic module (SDM) * Inflatable restraint steering wheel module * Inflatable restraint steering wheel module coil * Seat belt pretensioners Perform additional inspections on the following components: * Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. * Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, front end sensors, seat belt pretensioners, and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. * Passenger Presence System (PPS) for damage to the wiring or pressure system Accident With Side Air Bag Deployment - Component Replacement and Inspections After a collision involving side air bag deployment, replace the following components: * Inflatable restraint roof rail module, on the side of the impact. * Inflatable restraint side impact sensors (SIS) (left/right), on the side of the impact * Inflatable restraint side impact module (left/right), on the side of the impact * Inflatable restraint SDM * Seat belt pretensioner, on the side of impact. Perform additional inspections on the following components: * Mounting points or mounting hardware for the SIS, roof rail module (left/right), and seat belt pretensioner on the side of impact-Inspect for any Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 8843 damage and repair or replace each component as needed. * Mounting points or mounting hardware for the SDM and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. Sensor Replacement Guidelines The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. * Replace the sensor whether or not the air bags have deployed. * Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a diagnostic trouble code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 8848 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views Air Bag: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views > Page 8853 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views > Page 8854 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views > Page 8855 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views > Page 8856 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views > Page 8857 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views > Page 8858 Air Bag: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Harness Routing Views > Page 8859 Air Bag: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Front of the Headliner Components (ASF) 1 - Inflatable Restraint Roof Rail Module - Right 2 - Windshield 3 - Inflatable Restraint Roof Rail Module -Right Connector 4 - Inflatable Restraint Roof Rail Module - Right Connector Body Harness Side 5 - Inflatable Restraint Roof Rail Module - Left Connector Body Harness Side 6 - Inflatable Restraint Roof Rail Module - Left Connector 7 - Inflatable Restraint Roof Rail Module - Left Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 8860 Air Bag: Diagrams Component Connector End Views Inflatable Restraint I/P Module Inflatable Restraint Passenger Presence System (PPS) Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 8861 Inflatable Restraint Roof Rail Module - Left (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 8862 Inflatable Restraint Roof Rail Module - Right (ASF) Inflatable Restraint Steering Wheel Module X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 8863 Inflatable Restraint Steering Wheel Module X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) Air Bag: Service and Repair Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the head restraints from the front seats. Refer to Front Seat Head Restraint Replacement (See: Body and Frame/Seats/Head Rest/Service and Repair/Front Seat Head Restraint Replacement). 3. Lower the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 4. Disconnect the roof rail air bag electrical connector (1). 5. Remove the forward tether bolt (3). 6. Remove the clips (3) from the pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8866 7. Remove the 3 bolts retaining the rear curtain to the roof. 8. Remove the bolt retaining the bracket to the roof. 9. Remove the forward curtain clip (2). 10. Remove the 3 bolts (1, 3) retaining the air bag module to the roof. 11. Remove the roof rail air bag from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8867 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the 3 bolts (1, 3) retaining the roof rail air bag module to the roof. Tighten the roof rail air bag module bolts to 9 Nm (79 lb in). 2. Install the forward curtain clip (2). 3. Install the bolt retaining the bracket to the roof. 4. Install the 3 bolts retaining the rear curtain to the roof. Tighten the roof rail air bag curtain bolts to 9 Nm (79 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8868 5. Install the clips (3) to the pillar. 6. Install the roof rail air bag forward tether bolt (3). Tighten the roof rail air bag forward tether bolt to 9 Nm (79 lb in). 7. Connect the roof rail air bag electrical connector (1). 8. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 9. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 10. Install the head restraints from the front seats. Refer to Front Seat Head Restraint Replacement (See: Body and Frame/Seats/Head Rest/Service and Repair/Front Seat Head Restraint Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8869 Air Bag: Service and Repair Inflatable Restraint Roof Side Rail Module Replacement - Front (Regular and Extended Cab) Inflatable Restraint Roof Side Rail Module Replacement - Front (Regular and Extended Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the head restraints from the front seats. Refer to Front Seat Head Restraint Replacement (See: Body and Frame/Seats/Head Rest/Service and Repair/Front Seat Head Restraint Replacement). 3. Lower the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 4. Disconnect the roof rail air bag electrical connector (1). 5. Remove the forward tether bolt (3). 6. Remove the clips (3) from the pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8870 7. Remove the forward curtain clip (2). 8. Remove the 3 bolts (1) retaining the air bag module to the roof. 9. Remove the bolt (5) retaining the rear curtain to the roof. 10. Remove the rear tether bolt (3). 11. Remove the roof rail air bag from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the 3 bolts (1) retaining the roof rail air bag module to the roof. Tighten the roof rail air bag module bolts to 9 Nm (79 lb in). 2. Install a new forward curtain clip (2). 3. Install the bolt (5) retaining the rear curtain to the roof. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8871 Tighten the roof rail air bag curtain bolts to 9 Nm (79 lb in). 4. Install the rear tether bolt (3). Tighten the roof rail air bag rear tether bolt to 9 Nm (79 lb in). 5. Install the clips (3) to the pillar. 6. Install the roof rail air bag forward tether bolt (3). Tighten the roof rail air bag forward tether bolt to 9 Nm (79 lb in). 7. Connect the roof rail air bag electrical connector (1). 8. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 9. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 10. Install the head restraints from the front seats. Refer to Front Seat Head Restraint Replacement (See: Body and Frame/Seats/Head Rest/Service and Repair/Front Seat Head Restraint Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8872 Air Bag: Service and Repair Inflatable Restraint Steering Wheel Module Replacement Steering Wheel Inflatable Restraint Module Replacement Removal Procedure Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service Precautions/SIR Inflator Module Handling and Storage Warning). Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the inflatable restraint steering wheel module. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Locate the access holes (1) positioned on both sides of the steering wheel shroud. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8873 3. Using a 5.5 mm or 1/4 inch socket with a long 1/4 inch drive handle, push the leaf spring fasteners (1) inward through the access holes. 4. Lift and partially remove the inflatable restraint steering wheel module from the steering wheel in order to expose the electrical connectors. 5. Disconnect the electrical connectors (1). 6. Disconnect the horn electrical connector (3). Note: Do not attempt to repair the inflatable restraint steering wheel module. The inflatable restraint steering wheel module is replaced only as an assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8874 7. Remove the inflatable restraint module from the steering wheel. 8. Fully deploy the module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to Inflator Module Handling and Scrapping (See: ). Installation Procedure 1. Position the inflatable restraint module to the steering wheel. 2. Connect the electrical connectors (1) to the inflatable restraint steering wheel module. 3. Connect the horn electrical connector (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8875 4. Position the 4 alignment posts of the inflatable restraint module to the holes that are located on the steering wheel housing. 5. Push the inflatable restraint module into the steering wheel to engage and latch the leaf spring fasteners (1). 6. After installation, pull up on the sides of the inflatable restraint module to ensure the leaf spring fasteners are engaged. 7. Enable the inflatable restraint steering wheel module. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8876 Air Bag: Service and Repair Inflator Module Handling and Scrapping Inflator Module Handling and Scrapping Live and Undeployed Inflator Module Special Tools * J 38826 SIR Deployment Harness * J 39401-B SIR Deployment Fixture * An appropriate pigtail adapter Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service Precautions/SIR Inflator Module Handling and Storage Warning). Take special care when handling or storing an undeployed inflator module. An inflator module deployment produces a rapid generation of gas. This may cause the inflator module, or an object in front of the inflator module, to project through the air in the event of an unlikely deployment. Dual Stage Inflator Module Dual stage inflator modules have two deployment stages. If stage 1 was used to deploy a dual stage inflator module, stage 2 may still be active. Therefore, a deployed dual stage inflator module must be treated as an active module. If disposal of a dual stage module is required, both deployment loops must be energized to deploy the air bag. Scrapping Procedure During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live and undeployed inflator module. Do NOT dispose a live and undeployed inflator module through normal disposal channels until the inflator module has been deployed. Do not deploy the inflator module in the following situations: * After replacement of an inflator module under warranty, the inflator module may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a Product Liability report, GM-1241, related to the SIR system and is subject to a preliminary investigation, do NOT alter the SIR system in any manner. * If the vehicle is involved in a campaign affecting the inflator modules, follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures You can deploy the inflator module either inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation: Deployment Outside Vehicle - Steering Wheel Module, I/P Module, and Roof Rail Module Deploy the inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, you determine that the inflator module is malfunctioning. * The inflator module is cosmetically damaged, scratched, or ripped. * The inflator module pigtail is damaged. * The inflator module connector is damaged. * The inflator module connector terminals are damaged. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8877 Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. Warning In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflator module as normal shop waste. Undeployed inflator modules contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the inflator module. * If you are removing the steering wheel module, refer to Steering Wheel Inflatable Restraint Module Replacement (See: ). * If you are removing the I/P module, refer to Instrument Panel Inflatable Restraint Module Replacement (See: ). * If you are removing a roof rail module, refer to Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) (See: )Inflatable Restraint Roof Side Rail Module Replacement Front (Regular and Extended Cab) (See: ). Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service Precautions/SIR Inflator Module Handling and Storage Warning). 5. Place the inflator module on a work bench, with the vinyl trim cover facing up and away from the surface. 6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the inflator module or deployment fixture. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Ensure you have sufficient ventilation. 7. Clear the area of loose or flammable objects. Note: Dual stage deployments are only used in steering wheel and I/P inflator modules. If stage 1 was used to deploy a dual stage inflator module, stage 2 may still be active. If disposal of a dual stage module is required, both deployment loops must be energized to deploy the air bag. 8. If you are deploying a steering wheel inflator module, place the inflator module in the center of the space. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8878 9. When deploying an I/P inflator module, perform the following instructions: 1. Place the J 39401-B in the center of the cleared area. 2. Fill the deployment fixture with water or sand. 3. Using the proper nuts and bolts, mount the I/P module (1) to the deployment fixture (2), with the vinyl trim facing up. 4. Securely tighten all fasteners that hold the I/P module (1) to the deployment fixture (2). 10. When deploying a roof rail module, perform the following instructions: 1. Place the J 39401-B (3) in the center of the cleared area. 2. Fill the deployment fixture with water or sand to provide sufficient stabilization of fixture during deployment. 3. Adjust and secure the fixture arms (4) to the deployment fixture (3), using the proper nuts and bolts. 4. Attach the roof rail module in the deployment fixture and securely tighten all fasteners. 11. Inspect the SIR deployment harness and the appropriate pigtail adapter (2) for damage. Replace as needed. 12. Short the 2 SIR deployment harness leads (1) together using one banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8879 14. Extend the SIR deployment harness and adapter to the full length from the deployment fixture or area. Note: On a dual stage inflator module, both connectors must be attached to the deployment harness adapter. This will ensure that both stage 1 and stage 2 of the deployment loops are energized, regardless of the deployment state. 15. Connect the inflator module (1) to the adapter (2) on the SIR deployment harness (3). Note: * The rapid expansion of gas involved with deploying an inflator module is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. * When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module due to the force of the rapid expansion of gas inside the inflator module. * If you are deploying a dual stage inflator module with stage 1 already deployed, the fixture may not move and the noise may have been reduced. 16. Clear the area of people. 17. Separate the 2 banana plugs on the SIR deployment harness that were shorted together earlier in the procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8880 18. Place a 12-volt minimum/2-amp minimum power source, such as a vehicle battery, near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Deployment of the inflator module will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the inflator module deploys. 21. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure and contact the Technical Assistance Group. If deployment was successful, proceed to the following steps. Warning After deployment, the metal surfaces of the SIR component may be very hot. To help avoid a fire or personal injury: * Allow sufficient time for cooling before touching any metal surface of the SIR component. * Do not place the deployed SIR component near any flammable objects. 22. Seat one banana plug into the other in order to short the deployment harness leads. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the inflator module as soon as possible. 25. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 26. Dispose of the deployed inflator module through normal refuse channels. 27. Wash your hands with a mild soap. Deployment Inside Vehicle - Vehicle Scrapping Procedure Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes, but is not limited to, the following situations: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8881 * The vehicle has completed all useful life. * Irreparable damage occurred to the vehicle in a non-deployment type accident. * Irreparable damage occurred to the vehicle during a theft. * The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding as the same VIN. Warning When deploying a SIR component for disposal, perform the deployment procedures in the order listed. Failure to observe the procedures in the order listed may result in personal injury. 1. Lower the driver and passenger windows. 2. Turn the ignition switch to the OFF position and remove the ignition key. 3. Check that all inflator modules which will be deployed are mounted securely. * Driver inflator module is secured to the steering wheel. * Passenger inflator module is secured to the instrument panel. * Left roof rail inflator module is secured to the left roof rail. * Right roof rail inflator module is secured to the right roof rail. 4. Put on safety glasses. 5. Remove all loose objects from the front seats. Warning A deployed dual stage inflator module will look the same whether one or both stages were used. Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury. 6. Disconnect the steering wheel module yellow connector (1) from vehicle harness yellow connector (2). Note: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module will each have 4 wires. Refer to Component Connector End Views (See: Diagrams/Connector Views) for determining high and low circuits. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8882 7. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 8. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 9. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. Use these wires to fabricate the driver deployment harness. 10. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 11. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the inflator module. 12. Twist together the 2 connector wire leads from the high circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views) in order to determine the correct circuits. 13. Inspect that the 3-wire connection is secure. 14. Bend flat the twisted connection. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8883 15. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 16. Twist together the 2 connector wire leads from the low circuits from both stages of the steering wheel module, to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views) in order to determine the correct circuits. 17. Inspect that the 3-wire connection is secure. 18. Bend flat the twisted connection. 19. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 20. Connect the deployment harness to the connector on the steering wheel module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8884 21. Route the deployment harness out of the driver side of the vehicle. 22. Disconnect the yellow left roof rail harness connector from the vehicle harness connector. 23. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 24. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8885 25. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the roof rail air bag deployment harness. 26. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 27. Twist together one end from each of the wires in order to short the wires. 28. Twist together one connector wire lead to one deployment wire. 29. Bend flat the twisted connection. 30. Secure and insulate the connection using electrical tape. 31. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 32. Connect the deployment harness to the yellow connector of the roof rail module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8886 33. Route the deployment harness out of the driver side of the vehicle. 34. Disconnect the I/P module yellow harness connector (1) from the vehicle harness connector (2). Note: If the vehicle is equipped with dual stage air bags the steering wheel module and I/P module will each have 4 wires. Refer to Component Connector End Views (See: Diagrams/Connector Views) for determining high and low circuits. 35. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 36. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8887 37. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness. 38. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 39. Twist together one end from each of the wires in order to short the wires. 40. Twist together the 2 connector wire leads from the high circuits from both stages of the I/P module to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views) in order to determine the correct circuits. 41. Inspect that the 3-wire connection is secure. 42. Bend flat the twisted connection. 43. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8888 44. Twist together the 2 connector wire leads from the low circuits from both stages of the I/P module to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views) in order to determine the correct circuits. 45. Inspect that the 3-wire connection is secure. 46. Bend flat the twisted connection. 47. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 48. Connect the deployment harness to the I/P module in-line connector. 49. Route the deployment harness out of the passenger side of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8889 50. Disconnect the yellow harness connector to the right roof rail air bag from the vehicle harness connector. 51. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 52. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 53. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the roof rail module deployment harness. 54. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 55. Twist together one end from each of the wires in order to short the wires. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8890 56. Twist together one connector wire lead to one deployment wire. 57. Bend flat the twisted connection. 58. Secure and insulate the connection using electrical tape. 59. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8891 60. Connect the deployment harness to the roof rail module yellow connector. 61. Route the deployment harness out of the passenger side of the vehicle. 62. Completely cover the windshield and the front door window openings with a drop cloth. 63. Stretch to the full length all of the deployment harness wires on the right side of the vehicle. 64. Deploy each deployment loop one at a time. 65. Place a power source, 12 V minimum / 2 A minimum, such as a vehicle battery, near the shorted end of the harnesses. 66. Separate one set of wires and touch the wire ends to the power source in order to deploy the selected inflator module. 67. Disconnect the deployment harness from the power source and twist the wire ends together. 68. Continue the same process with the remaining deployment harnesses. 69. Stretch to the full length all of the deployment harness wires on the left side of the vehicle. 70. Deploy each deployment loop one at a time. 71. Place a power source, 12 V minimum / 2 A minimum, such as a vehicle battery, near the shorted end of the harnesses. 72. Separate one set of wires and touch the wires ends to the power source in order to deploy the selected inflator modules. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8892 73. Disconnect the deployment harness from the power source and twist the wire ends together. 74. Continue the same process with the remaining deployment harnesses. 75. Remove the drop cloth from the vehicle. 76. Disconnect all harnesses from the vehicle. 77. Discard the harnesses. 78. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 79. If one or all of the inflator modules did not deploy, perform the following steps to remove the undeployed modules from the vehicle: * Steering Wheel Inflatable Restraint Module Replacement (See: ) * Instrument Panel Inflatable Restraint Module Replacement (See: ) * Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) (See: )Inflatable Restraint Roof Side Rail Module Replacement - Front (Regular and Extended Cab) (See: ) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8893 Air Bag: Service and Repair Instrument Panel Inflatable Restraint Module Replacement Instrument Panel Inflatable Restraint Module Replacement Removal Procedure Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service Precautions/SIR Inflator Module Handling and Storage Warning). 1. Disable the SIR System. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the instrument panel (I/P) accessory trim panel. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 3. Remove the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 4. Remove the right access cover from the I/P end cap. 5. Remove the right air outlet. Refer to Instrument Panel Outer Air Outlet Replacement - Right Side (See: Heating and Air Conditioning/Air Register/Service and Repair/Instrument Panel Outer Air Outlet Replacement - Right Side). 6. Remove the I/P compartment door. Refer to Instrument Panel Compartment Door Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair). 7. Remove the digital radio receiver, if equipped. Refer to Digital Radio Receiver Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Digital Radio Receiver Replacement). 8. Access the 2 fasteners located above the service holes (1) inside the I/P compartment door opening. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8894 9. Remove the fasteners from the passenger supplemental inflatable restraint (PSIR) inflator module. 10. Remove the 2 side retaining nuts (1) from the PSIR module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8895 11. Partially remove the PSIR inflator module from the I/P. 12. Disconnect the connector position assurance (CPA). 13. Disconnect the electrical connector from the PSIR module. 14. Remove the PSIR inflator module from the vehicle. 15. Fully deploy the module before disposal. If the module is being replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to Inflator Module Handling and Scrapping (See: ). Note: If the PSIR module has deployed while attached to the I/P, the PSIR bracket MUST be replaced. 16. If replacing the PSIR bracket, remove the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 17. Remove the 2 fasteners retaining the PSIR bracket to the I/P structure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8896 18. Remove the PSIR bracket from the vehicle. Installation Procedure 1. If replacing the PSIR bracket, install the PSIR bracket to the I/P structure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8897 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 fasteners retaining the PSIR bracket to the I/P structure. Tighten the fasteners to 9 Nm (80 lb in). 3. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 4. Position the PSIR inflator module to the front of the I/P and connect the electrical connector. 5. Connect the CPA. 6. Install the PSIR inflator module to the I/P. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8898 7. Partially Install the 2 lower fasteners retaining the PSIR module to the I/P structure. 8. Install the 2 side retaining nuts (1) to the PSIR inflator module. Tighten the 4 PSIR fasteners until fully driven, seated and not stripped. 9. Install the digital radio receiver, if equipped. Refer to Digital Radio Receiver Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Digital Radio Receiver Replacement). 10. Install the radio. Refer to Radio Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 11. Install the I/P accessory trim panel. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 12. Install the right air outlet. Refer to Instrument Panel Outer Air Outlet Replacement - Right Side (See: Heating and Air Conditioning/Air Register/Service and Repair/Instrument Panel Outer Air Outlet Replacement - Right Side). 13. Install the right access cover to the I/P end cap. 14. Enable the SIR System. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 15. Install the I/P compartment door. Refer to Instrument Panel Compartment Door Replacement (See: Body and Frame/Interior Moulding / Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Inflatable Restraint Roof Side Rail Module Replacement - Front (Crew Cab) > Page 8899 Trim/Glove Compartment/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Relay > Component Information > Locations Air Bag Relay: Locations Component Connector End Views Relay Inflatable Restraint Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8906 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8907 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8908 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8909 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8910 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8911 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8912 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). 3. Cut the carpet along the "I" cut pattern over the inflatable restraint sensing and diagnostic module (SDM). 4. Fold the carpet back to expose the SDM. 5. Disconnect the electrical connector (2) from the SDM (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8913 6. Remove the nuts (2) retaining the SDM (1) to the floor studs (3). 7. Remove the SDM from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the SDM (1) to the floor studs (3) with 3 nuts (2). Tighten the SDM nuts to 9 Nm (79 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8914 2. Connect the electrical connector (2) to the SDM (1). 3. Fold the carpet back down over the SDM. 4. Install the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). Note: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 6. Program the SDM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures Clockspring Assembly / Spiral Cable: Procedures Inflatable Restraint Steering Wheel Module Coil Centering Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Note: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. 1. Verify the following conditions before centering the SIR coil: * The wheels on the vehicle are straight ahead. * The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. * The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 8919 1. Hold the SIR coil with the face up. 2. Rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 4. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the back side up. 2. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 3. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21/2 revolutions. 4. Release the spring service lock between locking tabs. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 1. Hold the SIR coil with the face up. 2. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 3. Rotate the coil hub, slowly, counterclockwise, for 21/2 revolutions. This is the CENTER position. 4. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 8920 Clockspring Assembly / Spiral Cable: Removal and Replacement Steering Wheel Inflatable Restraint Module Coil Replacement Removal Procedure Note: The inflatable restraint steering wheel module coil and the multifunction turn signal switch are serviced as an assembly. Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 3. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 4. Remove the wire harness straps from the wire harness assembly. 5. Disconnect any electrical connectors as needed. 6. Remove the inflatable restraint steering wheel module coil bolts. 7. Slide the inflatable restraint steering wheel module coil off of the steering column. Discard the inflatable restraint steering wheel module coil, if replacing. Installation Procedure Note: A new inflatable restraint steering wheel module coil will come precentered with a centering tab attached. Do NOT remove the centering tab until installation is complete. Failure to follow procedure will cause a misalignment and re-centering of the inflatable restraint steering wheel module coil will be required. If reusing the existing inflatable restraint steering wheel module coil, you must center the inflatable restraint steering wheel module coil. Refer to Inflatable Restraint Steering Wheel Module Coil Centering (See: Procedures). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 8921 1. Slide the inflatable restraint steering wheel module coil onto the steering column. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the inflatable restraint steering wheel module coil bolts. Tighten the bolts to 4.5 Nm (40 lb in). 3. Route the wiring harness assembly down the steering column. 4. Connect any electrical connectors as needed. 5. Install the wire harness straps to the wire harness assembly. 6. Remove the centering tab from the inflatable restraint steering wheel module coil, if equipped. 7. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 8. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 9. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Door Component Views Impact Sensor: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 8926 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 8927 Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 8928 Impact Sensor: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 8929 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 8930 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8931 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8932 Inflatable Restraint Passenger Presence System (PPS) Sensor Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8933 Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 3. Loosen the fasteners (1) retaining the front discriminating sensors to the radiator support. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8936 4. Remove the sensor assembly from the radiator support. 5. Position the sensor assembly, to gain access to the electrical connector. 6. Remove the connector-position assurance (CPA) from the sensor electrical connector. 7. Disconnect the sensor electrical connector. 8. Remove the sensor from the vehicle. Installation Procedure 1. Remove any dirt, grease, or other impurities from the mounting surfaces. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8937 2. Position the sensor near the radiator support. 3. Connect the sensor electrical connector. 4. Install the CPA to the sensor electrical connector. 5. Install the sensor assembly to the radiator support. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8938 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the 2 fasteners (1) retaining the discriminating sensor assembly to the radiator support. Tighten the bolts to 9 Nm (80 lb in). 7. Install the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8939 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Removal Procedure Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Fold back the carpet in order to gain access to the sensor. Refer to Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 3. Disconnect the electrical connector. 4. Remove the nuts securing the rollover sensor to the floor panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8940 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the nuts securing the rollover sensor to the floor panel. Tighten the screws to 10 Nm (88 lb in). 2. Connect the electrical connectors. 3. Install the carpet. Refer to Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 4. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8941 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor to the door. 5. Disconnect the impact sensor electrical connector from the side impact sensor. 6. Remove the side impact sensor from the door. Installation Procedure 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 8942 2. Position the side impact sensor horizontally to the door. 3. Connect the electrical connector to the side impact sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screws which retain the side impact sensor to the door. Tighten the screws to 9 Nm (79 lb in). 5. Fully seat the water deflector to the door. 6. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 7. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 8947 Seat Occupant Sensor: Locations Passenger Compartment/Roof Component Views Passenger Seat Components - 2 of 2 1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 8948 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Removal Procedure Warning Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 1. Remove the seat cushion trim cover and pad. 2. Disconnect the electrical connectors. 3. Remove the bolts that retain the electronic control unit (ECU) (1) from the bottom of the passenger seat cushion frame. 4. Remove the pressure switch (2) from the bottom of the passenger seat cushion frame. 5. Remove the push-in retainers (1) that hold the bladder to the seat cushion frame. 6. Remove the inflatable restraint passenger presence system from the seat. Installation Procedures 1. Install the inflatable restraint passenger presence system to the seat. 2. Install the push-in retainers (1) that hold the bladder to the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 8949 3. Install the pressure sensor (2) to the bottom of the passenger seat cushion frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolts that retain the ECU (1) to the bottom the passenger seat cushion frame. Tighten the bolts to 2 Nm (18 lb in). 5. Connect the electrical connectors. 6. Install the seat cushion trim cover and pad. 7. Re-zero the inflatable restraint passenger presence system. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Passenger Seat Components - 1 of 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 8953 1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger Under the Passenger Seat Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 8954 1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger (KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1) 7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 8955 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Left Inflatable Restraint Seat Position Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 8956 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement (Power Seat) Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). 2. Ensure that the seat is in the full rear position. 3. Locate the seat position sensor (1) under the seat on the inside of the inner seat rail. 4. Disconnect the electrical connector (3) from the seat position sensor (1). 5. Remove the 2 nuts (2) that retain the seat position sensor to the seat rail. 6. Remove the seat position sensor from the seat. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 8957 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the seat position sensor (1) to the seat rail with 2 nuts (2). Tighten the seat position sensor nuts to 9 Nm (79 lb in). 2. Connect the electrical connector (13) to the seat position sensor (1). 3. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8966 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8967 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8968 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8969 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8970 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8971 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8972 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). 3. Cut the carpet along the "I" cut pattern over the inflatable restraint sensing and diagnostic module (SDM). 4. Fold the carpet back to expose the SDM. 5. Disconnect the electrical connector (2) from the SDM (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8973 6. Remove the nuts (2) retaining the SDM (1) to the floor studs (3). 7. Remove the SDM from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the SDM (1) to the floor studs (3) with 3 nuts (2). Tighten the SDM nuts to 9 Nm (79 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8974 2. Connect the electrical connector (2) to the SDM (1). 3. Fold the carpet back down over the SDM. 4. Install the floor console. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair)Console Replacement (Small w/Manual Transmission) (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair). Note: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). 6. Program the SDM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Relay > Component Information > Locations Air Bag Relay: Locations Component Connector End Views Relay Inflatable Restraint Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 8982 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible Technical Service Bulletin # 10367 Date: 101206 Recall - Child Seat Top Tether Anchor Not Accessible FMVSS NONCOMPLIANCE Bulletin No.: 10367 Date: December 06, 2010 Subject: 10367 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating Position Models: 2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear Seats Equipped with a Front 60/40 Split Bench Seat Condition General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether anchor for the front center seat position in these vehicles is not accessible as required by the Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. Correction Unsold vehicles in dealer inventory, dealers are to modify the back panel trim cover to allow access to the top tether anchor and insert a supplement into the Owner Manual. Sold vehicles in customer hands, dealers are to provide a supplement to the Owner Manual that describes how to install a child restraint using a top tether in the center position. Dealers are to modify the back panel trim cover to allow access to the top tether anchor, if requested by the customer. Vehicles Involved Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat. All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is essential to routinely verify eligibility because not all similar vehicles may be involved regardless of description or option content. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Parts Information No parts are required for this recall. Service Procedure 1. For vehicles in dealer inventory, proceed to Step 3 and cut a hole in the back panel trim cover to allow access to the tether anchor. 2. For customer vehicles, provide the customer with a copy of the letter at the back of this bulletin (customers involved in this recall did not receive a letter) and after the customer has read the letter, ask the customer if they want this recall performed on their vehicle. DO NOT PERFORM THIS RECALL ON CUSTOMER VEHICLES WITHOUT THE CUSTOMER'S CONSENT. - If the customer does NOT want this recall performed on their vehicle, place a copy of the Owner Manual Supplement (located at the end of this service procedure) in the Owner Manual. No further action is required. Submit a transaction using labor code T5799. - If the customer DOES want this recall performed on their vehicle, proceed to the following step. 3. Move the driver and passenger seats to the full-forward position. 4. Remove the tether access cover. The cover is located on the passenger side of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 8992 5. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether access hole to the center of the second (center) tether access point. Mark the center of the hole with a pen. 6. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the trim panel upward to the measurement and cross mark the location made in Step 5. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 8993 Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more than 12 mm (3/16 in) from the outside edge of the hole saw. 7. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether access anchor point. Use the marks made in Steps 5 and 6 as your center point for the cut. 8. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in the illustration. 9. Clean the debris from the floor using a vacuum cleaner. 10. Reinstall the tether access cover over the passenger side tether access point. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 8994 11. Move the driver and passenger seats back to the desired position. 12. Place a copy of the 2-page Owner Manual Supplement (found below) in the Owner Manual in the glove compartment. THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED IN YOUR OWNER MANUAL Where to Put the Restraint According to accident statistics, children and infants are safer when properly restrained in a child restraint system or infant restraint system secured in a rear seating position. General Motors recommends that children and child restraints be secured in a rear seat, including: an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat; an older child riding in a booster seat; and children, who are large enough, using safety belts. Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so great, if the airbag deploys. Warning A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates. This is because the back of the rear-facing child restraint would be very close to the inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates and the passenger seat is in a forward position. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. Even if the passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not deploy under some unusual circumstance, even though it is turned off. Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a forward-facing child restraint in the right front seat, always move the front passenger seat as far back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a rear seat. See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for additional information. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. Do not use child restraints in the center front seat position. General Motors understands that there may be certain circumstances where it is necessary to transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for instructions on how to install a child restraint in the right front seat position. Securing Forward-Facing Child Restraints (Center Front Seat Position) For vehicles without rear seats, manufacturers are required to provide top tether anchors for all non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is available, you should not install a child restraint in the center front seating position. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. In addition, some larger child restraints, if installed in the center front seating position, may interfere with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the vehicle owner manual for information, including warnings, about the importance of safety belt use. If you must transport a forward-facing child restraint in the center front seat position, you must have a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your vehicle does not already have a hole, you must have a service procedure performed on your vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. This service procedure will be performed for you at no charge. The lap belt would be used to secure a child restraint in this position, following the instructions that came with the child restraint. 1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the passenger seat so that the seat and seatback are aligned with the driver seat and seatback positions. See the appropriate section in the vehicle owner manual for more information on adjusting the Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 8995 seat and seatback. 2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a top tether anchor, attach the top tether on the child restraint to the top tether anchor on the vehicle. Route the top tether according to the child restraint instructions and the following instructions: 1. Route the top tether over the center seatback or folding armrest, if equipped. 2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this time. 4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through the restraint. The child restraint instructions will show you how. 5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose end of the belt. It may be helpful to use your knee to push down on the child restraint as you tighten the belt. 7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint at the safety belt path and attempt to move it side to side and back and forth. When the child restraint is properly installed, there should be no more than 2.5 cm (1 in) of movement. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in Net Item should be the actual cost of a 2.5 in (63.5 mm) hole saw, not to exceed $15.00 USD, $15.04 CAD. Customer Notification General Motors did not notify customers involved in this recall. The customer names and addresses were not available. If a customer involved in this recall comes into your dealership, please provide them with a copy of the customer letter included with this bulletin. Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible if requested by the customer. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 8996 This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your facility may be subject to a civil penalty for each such sale. Dealer Recall Responsibility All unsold new vehicles in dealer's possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your facility for service in the future, you must take the steps necessary to be sure the recall correction has been addressed before selling or releasing the vehicle. Note For involved customer vehicles that visit your dealership for service, addressing the recall correction involves obtaining the customer's permission to perform the required repair. Disclaimer Owner Letter Owner Letter December 2010 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible and the Owner Manual does not include instructions regarding how to use the top tether. As a result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important Your vehicle is involved in recall 10367. This recall notice contains important information and instructions to the use of child restraints in your vehicle. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The child restraint top tether anchor for the front center seat position in your vehicle is not accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. The top tether helps to secure a child seat. Even with the top tether, however, both the National Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In the event of a crash, a child in a child restraint in the front center seat position with or without a top tether anchor restraint can be seriously injured or killed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 8997 What will we do? FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how to install a child restraint using a top tether in the front center seat position; however, General Motors does not recommend that you place a child restraint in the front center seat. A child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate. If you must transport a child in a forward-facing child restraint in your vehicle, General Motors recommends placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off switch that is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver's frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the passenger airbag is off. Please refer to the appropriate section in your Owner Manual for more information. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. See the enclosed insert for an illustration. This service procedure will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 20 minutes. What should you do? Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and Restraints section for future reference. Because a child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front center seat position. You should contact your GM dealer to arrange a service appointment to have an access hole cut into the back panel trim cover as soon as possible. Until this recall can be performed on your vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center seat position. After this procedure has been performed by your dealer, the Owner Manual Supplement provides a step-by-step procedure for attaching a child restraint top tether to the vehicle top tether anchor for the front center seat position. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services Enclosure 10367 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat Technical Service Bulletin # 10407 Date: 101206 Recall - Child Restraint No Access, Front Center Seat FMVSS NONCOMPLIANCE Bulletin No.: 10407 Date: December 06, 2010 Subject: 10407 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating Position Models: 2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear Seats Equipped with a Front 60/40 Split Bench Seat Condition General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether anchor for the front center seat position in these vehicles is not accessible as required by the Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. Correction Customers will be mailed an Owner Manual Supplement that describes how to install a child restraint using a top tether in the center position. Dealers are to modify the back panel trim cover to allow access to the top tether anchor, if requested by the customer. Vehicles Involved Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat. All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. Parts Information No parts are required for this recall. Service Procedure Note Do NOT perform this service procedure unless the customer has requested it. 1. Move the driver and passenger seats to the full-forward position. 2. Remove the tether access cover. The cover is located on the passenger side of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9002 3. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether access hole to the center of the second (center) tether access point. Mark the center of the hole with a pen. 4. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the trim panel upward to the measurement and cross mark the location made in Step 5. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9003 Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more than 12 mm (3/16 in) from the outside edge of the hole saw. 5. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether access anchor point. Use the marks made in Steps 5 and 6 as your center point for the cut. 6. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in the illustration. 7. Clean the debris from the floor using a vacuum cleaner. 8. Reinstall the tether access cover over the passenger side tether access point. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9004 9. Move the driver and passenger seats back to the desired position. Warranty Transaction Information Submit a transaction using the table below. Customer Notification General Motors will notify customers of this Noncompliance Special Coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible if requested by the customer. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your facility may be subject to a civil penalty for each such sale. Dealer Recall Responsibility - All Dealers are to service all vehicles subject to this noncompliance special coverage at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward if the customer requests the repair. THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED IN YOUR OWNER MANUAL Where to Put the Restraint According to accident statistics, children and infants are safer when properly restrained in a child restraint system or infant restraint system secured in a rear seating position. General Motors recommends that children and child restraints be secured in a rear seat, including: an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat; an older child riding in a booster seat; and children, who are large enough, using safety belts. Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so great, if the airbag deploys. Warning A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates. This is because the back of the rear-facing child restraint would be very close to the inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates and the passenger seat is in a forward position. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. Even if the passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not deploy under some unusual circumstance, even though it is turned off. Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a forward-facing child restraint in the right front seat, always move the front passenger seat as far back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a rear seat. See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for additional information. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9005 Do not use child restraints in the center front seat position. General Motors understands that there may be certain circumstances where it is necessary to transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for instructions on how to install a child restraint in the right front seat position. Securing Forward-Facing Child Restraints (Center Front Seat Position) For vehicles without rear seats, manufacturers are required to provide top tether anchors for all non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is available, you should not install a child restraint in the center front seating position. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. In addition, some larger child restraints, if installed in the center front seating position, may interfere with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the vehicle owner manual for information, including warnings, about the importance of safety belt use. If you must transport a forward-facing child restraint in the center front seat position, you must have a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your vehicle does not already have a hole, you must have a service procedure performed on your vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. This service procedure will be performed for you at no charge. The lap belt would be used to secure a child restraint in this position, following the instructions that came with the child restraint. 1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the passenger seat so that the seat and seatback are aligned with the driver seat and seatback positions. See the appropriate section in the vehicle owner manual for more information on adjusting the seat and seatback. 2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a top tether anchor, attach the top tether on the child restraint to the top tether anchor on the vehicle. Route the top tether according to the child restraint instructions and the following instructions: 1. Route the top tether over the center seatback or folding armrest, if equipped. 2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this time. 4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through the restraint. The child restraint instructions will show you how. 5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose end of the belt. It may be helpful to use your knee to push down on the child restraint as you tighten the belt. 7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint at the safety belt path and attempt to move it side to side and back and forth. When the child restraint is properly installed, there should be no more than 2.5 cm (1 in) of movement. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9006 Disclaimer Owner Letter Owner Letter December 2010 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible and the Owner Manual does not include instructions regarding how to use the top tether. As a result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in Noncompliance Special Coverage 10407. - This notice contains important information and instructions to the use of child restraints in your vehicle. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The child restraint top tether anchor for the front center seat position in your vehicle is not accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. The top tether helps to secure a child seat. Even with the top tether, however, both the National Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In the event of a crash, a child in a child restraint in the front center seat position with or without a top tether anchor restraint can be seriously injured or killed. What will we do? FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how to install a child restraint using a top tether in the front center seat position; however, General Motors does not recommend that you place a child restraint in the front center seat. A child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate. If you must transport a child in a forward-facing child restraint in your vehicle, General Motors recommends placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual on-off switch that is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver's frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the passenger airbag is off. Please refer to the appropriate section in your Owner Manual for more information. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. See the enclosed insert for an illustration. This service procedure will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 20 minutes. What should you do? Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and Restraints section for future reference. Because a child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front center seat position. You should contact your GM dealer to arrange a service appointment to have an access hole cut into the back panel trim cover as soon as possible. Until this recall can be performed on your vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center seat position. After Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9007 this procedure has been performed by your dealer, the Owner Manual Supplement provides a step-by-step procedure for attaching a child restraint top tether to the vehicle top tether anchor for the front center seat position. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services Enclosure 10407 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > NHTSA10V575000 > Nov > 10 > Recall 10V575000: Child Restraint Non-Compliance Child Seat Tether Attachment: Recalls Recall 10V575000: Child Restraint Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2011 GMC/Canyon 2004-2011 Isuzu/I-280/I-350 2006 Isuzu/I-290/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: November 18, 2010 NHTSA CAMPAIGN ID NUMBER: 10V575000 NHTSA ACTION NUMBER: N/A COMPONENT: Child Seat POTENTIAL NUMBER OF UNITS AFFECTED: 192,676 SUMMARY: GM is recalling certain model year 2004-2011, Chevrolet Colorado, GMC Canyon, model year 2006, Isuzu I-280/I-350, and model year 2007-2008, I-290/I-370, regular cab vehicles and extended cab vehicles without a rear seat and equipped with a front 60/40 split bench seat. These vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 225, "Child Restraint Anchorage Systems." The top tether anchor for the front center seat is not accessible and the owners manual does not include instructions regarding how to use the top tether. CONSEQUENCE: Both NHTSA and GM discourage placement of a child in a front seat. Nevertheless, there are individual circumstances that may require placement of a child in a restraint in the front center seating position of this vehicle that does not offer a rear seat. Lack of access to the top tether anchor and a lack of instructions as to how to use it, may result in improper installation of a child restraint. Improper installation of a child restraint can result in a reduction in the restraint's performance in the event of a crash and an increased risk of injury or death to the child seated in the restraint. REMEDY: Dealers will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position and will provide supplemental information as to use in the owner's manual. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or visit GM'S website at www.gmownercenter.com. NOTES: GM safety recall No. 10367. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible Technical Service Bulletin # 10367 Date: 101206 Recall - Child Seat Top Tether Anchor Not Accessible FMVSS NONCOMPLIANCE Bulletin No.: 10367 Date: December 06, 2010 Subject: 10367 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating Position Models: 2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear Seats Equipped with a Front 60/40 Split Bench Seat Condition General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether anchor for the front center seat position in these vehicles is not accessible as required by the Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. Correction Unsold vehicles in dealer inventory, dealers are to modify the back panel trim cover to allow access to the top tether anchor and insert a supplement into the Owner Manual. Sold vehicles in customer hands, dealers are to provide a supplement to the Owner Manual that describes how to install a child restraint using a top tether in the center position. Dealers are to modify the back panel trim cover to allow access to the top tether anchor, if requested by the customer. Vehicles Involved Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat. All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is essential to routinely verify eligibility because not all similar vehicles may be involved regardless of description or option content. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Parts Information No parts are required for this recall. Service Procedure 1. For vehicles in dealer inventory, proceed to Step 3 and cut a hole in the back panel trim cover to allow access to the tether anchor. 2. For customer vehicles, provide the customer with a copy of the letter at the back of this bulletin (customers involved in this recall did not receive a letter) and after the customer has read the letter, ask the customer if they want this recall performed on their vehicle. DO NOT PERFORM THIS RECALL ON CUSTOMER VEHICLES WITHOUT THE CUSTOMER'S CONSENT. - If the customer does NOT want this recall performed on their vehicle, place a copy of the Owner Manual Supplement (located at the end of this service procedure) in the Owner Manual. No further action is required. Submit a transaction using labor code T5799. - If the customer DOES want this recall performed on their vehicle, proceed to the following step. 3. Move the driver and passenger seats to the full-forward position. 4. Remove the tether access cover. The cover is located on the passenger side of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9017 5. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether access hole to the center of the second (center) tether access point. Mark the center of the hole with a pen. 6. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the trim panel upward to the measurement and cross mark the location made in Step 5. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9018 Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more than 12 mm (3/16 in) from the outside edge of the hole saw. 7. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether access anchor point. Use the marks made in Steps 5 and 6 as your center point for the cut. 8. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in the illustration. 9. Clean the debris from the floor using a vacuum cleaner. 10. Reinstall the tether access cover over the passenger side tether access point. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9019 11. Move the driver and passenger seats back to the desired position. 12. Place a copy of the 2-page Owner Manual Supplement (found below) in the Owner Manual in the glove compartment. THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED IN YOUR OWNER MANUAL Where to Put the Restraint According to accident statistics, children and infants are safer when properly restrained in a child restraint system or infant restraint system secured in a rear seating position. General Motors recommends that children and child restraints be secured in a rear seat, including: an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat; an older child riding in a booster seat; and children, who are large enough, using safety belts. Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so great, if the airbag deploys. Warning A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates. This is because the back of the rear-facing child restraint would be very close to the inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates and the passenger seat is in a forward position. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. Even if the passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not deploy under some unusual circumstance, even though it is turned off. Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a forward-facing child restraint in the right front seat, always move the front passenger seat as far back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a rear seat. See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for additional information. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. Do not use child restraints in the center front seat position. General Motors understands that there may be certain circumstances where it is necessary to transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for instructions on how to install a child restraint in the right front seat position. Securing Forward-Facing Child Restraints (Center Front Seat Position) For vehicles without rear seats, manufacturers are required to provide top tether anchors for all non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is available, you should not install a child restraint in the center front seating position. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. In addition, some larger child restraints, if installed in the center front seating position, may interfere with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the vehicle owner manual for information, including warnings, about the importance of safety belt use. If you must transport a forward-facing child restraint in the center front seat position, you must have a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your vehicle does not already have a hole, you must have a service procedure performed on your vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. This service procedure will be performed for you at no charge. The lap belt would be used to secure a child restraint in this position, following the instructions that came with the child restraint. 1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the passenger seat so that the seat and seatback are aligned with the driver seat and seatback positions. See the appropriate section in the vehicle owner manual for more information on adjusting the Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9020 seat and seatback. 2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a top tether anchor, attach the top tether on the child restraint to the top tether anchor on the vehicle. Route the top tether according to the child restraint instructions and the following instructions: 1. Route the top tether over the center seatback or folding armrest, if equipped. 2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this time. 4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through the restraint. The child restraint instructions will show you how. 5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose end of the belt. It may be helpful to use your knee to push down on the child restraint as you tighten the belt. 7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint at the safety belt path and attempt to move it side to side and back and forth. When the child restraint is properly installed, there should be no more than 2.5 cm (1 in) of movement. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in Net Item should be the actual cost of a 2.5 in (63.5 mm) hole saw, not to exceed $15.00 USD, $15.04 CAD. Customer Notification General Motors did not notify customers involved in this recall. The customer names and addresses were not available. If a customer involved in this recall comes into your dealership, please provide them with a copy of the customer letter included with this bulletin. Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible if requested by the customer. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9021 This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your facility may be subject to a civil penalty for each such sale. Dealer Recall Responsibility All unsold new vehicles in dealer's possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your facility for service in the future, you must take the steps necessary to be sure the recall correction has been addressed before selling or releasing the vehicle. Note For involved customer vehicles that visit your dealership for service, addressing the recall correction involves obtaining the customer's permission to perform the required repair. Disclaimer Owner Letter Owner Letter December 2010 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible and the Owner Manual does not include instructions regarding how to use the top tether. As a result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important Your vehicle is involved in recall 10367. This recall notice contains important information and instructions to the use of child restraints in your vehicle. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The child restraint top tether anchor for the front center seat position in your vehicle is not accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. The top tether helps to secure a child seat. Even with the top tether, however, both the National Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In the event of a crash, a child in a child restraint in the front center seat position with or without a top tether anchor restraint can be seriously injured or killed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10367 > Dec > 10 > Recall - Child Seat Top Tether Anchor Not Accessible > Page 9022 What will we do? FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how to install a child restraint using a top tether in the front center seat position; however, General Motors does not recommend that you place a child restraint in the front center seat. A child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate. If you must transport a child in a forward-facing child restraint in your vehicle, General Motors recommends placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off switch that is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver's frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the passenger airbag is off. Please refer to the appropriate section in your Owner Manual for more information. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. See the enclosed insert for an illustration. This service procedure will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 20 minutes. What should you do? Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and Restraints section for future reference. Because a child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front center seat position. You should contact your GM dealer to arrange a service appointment to have an access hole cut into the back panel trim cover as soon as possible. Until this recall can be performed on your vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center seat position. After this procedure has been performed by your dealer, the Owner Manual Supplement provides a step-by-step procedure for attaching a child restraint top tether to the vehicle top tether anchor for the front center seat position. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services Enclosure 10367 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat Technical Service Bulletin # 10407 Date: 101206 Recall - Child Restraint No Access, Front Center Seat FMVSS NONCOMPLIANCE Bulletin No.: 10407 Date: December 06, 2010 Subject: 10407 - Child Restraint Top Tether Anchor Not Accessible for Front Center Seating Position Models: 2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon Regular Cab, Extended Cab without Rear Seats Equipped with a Front 60/40 Split Bench Seat Condition General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225, (CMVSS) 210.1, Child Restraint Anchorage Systems. The child restraint top tether anchor for the front center seat position in these vehicles is not accessible as required by the Standard. Without the top tether anchor, the child restraint may not be properly secured. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. Correction Customers will be mailed an Owner Manual Supplement that describes how to install a child restraint using a top tether in the center position. Dealers are to modify the back panel trim cover to allow access to the top tether anchor, if requested by the customer. Vehicles Involved Involved are certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat. All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. Parts Information No parts are required for this recall. Service Procedure Note Do NOT perform this service procedure unless the customer has requested it. 1. Move the driver and passenger seats to the full-forward position. 2. Remove the tether access cover. The cover is located on the passenger side of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9027 3. Using a tape measure and pen, measure 341 mm (13 7/16 in) from the inboard side of the tether access hole to the center of the second (center) tether access point. Mark the center of the hole with a pen. 4. Using a tape measure and pen, measure and mark 461 mm (18 1/8 in) from the bottom of the trim panel upward to the measurement and cross mark the location made in Step 5. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9028 Note To avoid damaging the sheet metal behind the trim panel, the drill bit must NOT extend more than 12 mm (3/16 in) from the outside edge of the hole saw. 5. Using a 63.5 mm (2.5 in) hole saw, cut a hole in the panel to gain access to the center tether access anchor point. Use the marks made in Steps 5 and 6 as your center point for the cut. 6. Clean the edge of the hole with a file. The actual hole will appear slightly larger than shown in the illustration. 7. Clean the debris from the floor using a vacuum cleaner. 8. Reinstall the tether access cover over the passenger side tether access point. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9029 9. Move the driver and passenger seats back to the desired position. Warranty Transaction Information Submit a transaction using the table below. Customer Notification General Motors will notify customers of this Noncompliance Special Coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible if requested by the customer. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your facility may be subject to a civil penalty for each such sale. Dealer Recall Responsibility - All Dealers are to service all vehicles subject to this noncompliance special coverage at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward if the customer requests the repair. THIS INFORMATION IS IN ADDITION TO THE CHILD RESTRAINT INFORMATION CONTAINED IN YOUR OWNER MANUAL Where to Put the Restraint According to accident statistics, children and infants are safer when properly restrained in a child restraint system or infant restraint system secured in a rear seating position. General Motors recommends that children and child restraints be secured in a rear seat, including: an infant or a child riding in a rear-facing child restraint; a child riding in a forward-facing child seat; an older child riding in a booster seat; and children, who are large enough, using safety belts. Never put a rear-facing child seat in the front. This is because the risk to the rear-facing child is so great, if the airbag deploys. Warning A child in a rear-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates. This is because the back of the rear-facing child restraint would be very close to the inflating airbag. A child in a forward-facing child restraint can be seriously injured or killed if the right front passenger airbag inflates and the passenger seat is in a forward position. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. Even if the passenger sensing system or manual airbag on-off switch, if equipped, has turned off the right front passenger frontal airbag, no system is fail-safe. No one can guarantee that an airbag will not deploy under some unusual circumstance, even though it is turned off. Secure rear-facing child restraints in a rear seat, even if the airbag is off. If you secure a forward-facing child restraint in the right front seat, always move the front passenger seat as far back as it will go. It is better to secure the child restraint in the back of a vehicle equipped with a rear seat. See "Passenger Sensing System" or "Airbag On-Off Switch" in the vehicle owner manual for additional information. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9030 Do not use child restraints in the center front seat position. General Motors understands that there may be certain circumstances where it is necessary to transport a child in a forward-facing child restraint in your vehicle. In these cases, we recommend placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual airbag on-off switch which is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the airbag is off. See "Child Restraints" in the vehicle owner manual for instructions on how to install a child restraint in the right front seat position. Securing Forward-Facing Child Restraints (Center Front Seat Position) For vehicles without rear seats, manufacturers are required to provide top tether anchors for all non-driver seating positions and instructions for using those anchors. Even if a top tether anchor is available, you should not install a child restraint in the center front seating position. Warning A child in a child restraint in the center front seat can be badly injured or killed by the frontal airbags if they inflate. Never secure a child restraint in the center front seat. It is always better to secure a child restraint in a rear seat. In addition, some larger child restraints, if installed in the center front seating position, may interfere with access to the driver and right front passenger safety belt buckles. See "Safety Belts" in the vehicle owner manual for information, including warnings, about the importance of safety belt use. If you must transport a forward-facing child restraint in the center front seat position, you must have a hole in the back panel trim cover to allow access to the top tether anchor for that position. If your vehicle does not already have a hole, you must have a service procedure performed on your vehicle prior to securing a forward-facing child restraint in the center front seat position. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. This service procedure will be performed for you at no charge. The lap belt would be used to secure a child restraint in this position, following the instructions that came with the child restraint. 1. Adjust the driver seat to the desired driving position. Fold the armrest up, if equipped. Move the passenger seat so that the seat and seatback are aligned with the driver seat and seatback positions. See the appropriate section in the vehicle owner manual for more information on adjusting the seat and seatback. 2. Place the child restraint on the seat. 3. If the child restraint manufacturer recommends using a top tether anchor, attach the top tether on the child restraint to the top tether anchor on the vehicle. Route the top tether according to the child restraint instructions and the following instructions: 1. Route the top tether over the center seatback or folding armrest, if equipped. 2. Attach the top tether to the slots in the back panel as shown. Do not tighten the top tether at this time. 4. Pick up the latch plate on the center position lap safety belt, and run the lap safety belt through the restraint. The child restraint instructions will show you how. 5. Push the latch plate into the buckle until it clicks. Position the release button on the buckle so that the safety belt can be unbuckled. 6. Tighten the center position lap belt by pulling on the loose end of the belt. It may be helpful to use your knee to push down on the child restraint as you tighten the belt. 7. Tighten the top tether. Follow the child restraint manufacturer's instructions. 8. Before placing a child in the child restraint, make sure it is securely held in place. To check, grasp the child restraint at the safety belt path and attempt to move it side to side and back and forth. When the child restraint is properly installed, there should be no more than 2.5 cm (1 in) of movement. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9031 Disclaimer Owner Letter Owner Letter December 2010 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that certain 2004-2011 model year Chevrolet Colorado and GMC Canyon regular cab vehicles and extended cab vehicles without a rear seat, and equipped with a front 60/40 split bench seat fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 225 and (CMVSS) 210.1. The top tether anchor for the front center seat is not accessible and the Owner Manual does not include instructions regarding how to use the top tether. As a result, GM is conducting a recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in Noncompliance Special Coverage 10407. - This notice contains important information and instructions to the use of child restraints in your vehicle. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The child restraint top tether anchor for the front center seat position in your vehicle is not accessible as required by the Standard. FMVSS 225 also requires that the Owner Manual includes a step-by-step procedure for attaching a child restraint top tether to a vehicle top tether anchor. The top tether helps to secure a child seat. Even with the top tether, however, both the National Highway Traffic Safety Administration and GM discourage placement of a child in a front seat. In the event of a crash, a child in a child restraint in the front center seat position with or without a top tether anchor restraint can be seriously injured or killed. What will we do? FMVSS 225 requires that we provide the enclosed Owner Manual Supplement that describes how to install a child restraint using a top tether in the front center seat position; however, General Motors does not recommend that you place a child restraint in the front center seat. A child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate. If you must transport a child in a forward-facing child restraint in your vehicle, General Motors recommends placing the forward-facing child restraint in the right front passenger seat where a top tether anchor is already accessible. The vehicle may have a passenger sensing system or a manual on-off switch that is designed to turn off the right front passenger frontal airbag under certain conditions. In addition, a forward-facing child restraint installed in the right front passenger seat would not interact with the driver's frontal airbag. Rear-facing child restraints should not be installed in vehicles without a rear seat, even if the passenger airbag is off. Please refer to the appropriate section in your Owner Manual for more information. Your GM dealer will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position. See the enclosed insert for an illustration. This service procedure will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 20 minutes. What should you do? Please place the enclosed Owner Manual Supplement in your Owner Manual in the Seats and Restraints section for future reference. Because a child in a child restraint in the front center seat position can be seriously injured or killed by the frontal airbags if they inflate, GM does not recommend installing child restraints in the front center seat position. You should contact your GM dealer to arrange a service appointment to have an access hole cut into the back panel trim cover as soon as possible. Until this recall can be performed on your vehicle, a child restraint top tether cannot be attached to the top tether anchor for the front center seat position. After Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 10407 > Dec > 10 > Recall - Child Restraint No Access, Front Center Seat > Page 9032 this procedure has been performed by your dealer, the Owner Manual Supplement provides a step-by-step procedure for attaching a child restraint top tether to the vehicle top tether anchor for the front center seat position. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services Enclosure 10407 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > NHTSA10V575000 > Nov > 10 > Recall 10V575000: Child Restraint Non-Compliance Child Seat Tether Attachment: All Technical Service Bulletins Recall 10V575000: Child Restraint Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2011 GMC/Canyon 2004-2011 Isuzu/I-280/I-350 2006 Isuzu/I-290/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: November 18, 2010 NHTSA CAMPAIGN ID NUMBER: 10V575000 NHTSA ACTION NUMBER: N/A COMPONENT: Child Seat POTENTIAL NUMBER OF UNITS AFFECTED: 192,676 SUMMARY: GM is recalling certain model year 2004-2011, Chevrolet Colorado, GMC Canyon, model year 2006, Isuzu I-280/I-350, and model year 2007-2008, I-290/I-370, regular cab vehicles and extended cab vehicles without a rear seat and equipped with a front 60/40 split bench seat. These vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 225, "Child Restraint Anchorage Systems." The top tether anchor for the front center seat is not accessible and the owners manual does not include instructions regarding how to use the top tether. CONSEQUENCE: Both NHTSA and GM discourage placement of a child in a front seat. Nevertheless, there are individual circumstances that may require placement of a child in a restraint in the front center seating position of this vehicle that does not offer a rear seat. Lack of access to the top tether anchor and a lack of instructions as to how to use it, may result in improper installation of a child restraint. Improper installation of a child restraint can result in a reduction in the restraint's performance in the event of a crash and an increased risk of injury or death to the child seated in the restraint. REMEDY: Dealers will cut a hole into the back panel trim cover to allow access to the top tether anchor for the front center seat position and will provide supplemental information as to use in the owner's manual. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or visit GM'S website at www.gmownercenter.com. NOTES: GM safety recall No. 10367. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 9037 Child Seat Tether Attachment: Service and Repair Child Seat Restraint System Belt Bracket Replacement Removal Procedure 1. Remove the bolt securing the child seat restraint bracket to the vehicle. 2. Remove the child seat restraint bracket from the vehicle. Installation Procedure 1. Position the child seat restraint bracket by hooking the 2 tabs on the rear of the bracket into the slots in the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the child seat restraint bracket to the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 9038 Tighten the child seat restraint bracket bolt to 52.5 Nm (39 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 9043 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) Seat Belt: Service and Repair Front Seat Belt Replacement (Crew Cab) Front Seat Belt Replacement (Crew Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt upper guide shoulder bolt. 4. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly to the body. 8. Remove the front seat belt assembly from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9046 1. Position the rear seat belt retractor/pretensioner assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body. Tighten the front seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft). 3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the front seat belt upper guide shoulder bolt trim cover. 6. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9047 Seat Belt: Service and Repair Front Seat Belt Replacement (Regular and Extended Cab) Front Seat Belt Replacement (Regular and Extended Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Open the front seat belt upper guide shoulder bolt trim cover (4). 3. Remove the front seat belt upper guide shoulder bolt (5). 4. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). On extended cab models, the front seat belt retractor/pretensioner is located in the rear door, not the rear corner of the cab. 5. Remove the front seat belt anchor bolt (2). 6. Disconnect the electrical connector from the retractor/pretensioner (1). 7. Remove the bolt (3) that retains the seat belt retractor/pretensioner assembly to the body. 8. Remove the front seat belt assembly from the vehicle. Installation Procedure 1. Position the rear seat belt retractor/pretensioner assembly to the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9048 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt (3) which retains the seat belt retractor/pretensioner assembly (1) to the body. Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft). 3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper guide with the bolt (5). Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the front seat belt upper guide shoulder bolt trim cover (4). 6. Install the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9049 Seat Belt: Service and Repair Front Seat Center Belt Replacement Front Seat Center Belt Replacement Removal Procedure 1. Remove the rear inboard seat bolt (1) from the passenger seat. 2. Remove the grommet securing the center seat belt assembly (2) to the seat adjuster. 3. Remove the center seat belt assembly. Installation Procedure 1. Position the center seat belt assembly (2) over the rear inboard seat adjuster mounting hole. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9050 2. Install the front seat mounting bolt (1). Tighten the front seat mounting bolt to 52.5 Nm (39 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9051 Seat Belt: Service and Repair Rear Seat Belt Replacement Rear Seat Belt Replacement Removal Procedure 1. Open the rear seat belt upper guide shoulder bolt trim cover. 2. Remove the rear seat belt upper guide shoulder bolt. 3. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Remove the rear seat belt anchor bolt. 5. Remove the bolt that retains the seat belt retractor assembly to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9052 6. Remove the rear seat belt assembly from the vehicle. Installation Procedure 1. Position the rear seat belt retractor assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the seat belt retractor assembly to the body. Tighten the rear seat belt retractor bolt to 52.5 Nm (39 lb ft). 3. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the rear seat belt upper guide bolt to 52.5 Nm (39 lb ft). 4. Install the rear seat belt upper guide shoulder bolt trim cover. 5. Install the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9053 6. Install the rear seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the rear seat belt anchor bolt to 52.5 Nm (39 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9054 Seat Belt: Service and Repair Front Seat Belt Replacement (Crew Cab) Front Seat Belt Replacement (Crew Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt upper guide shoulder bolt. 4. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly to the body. 8. Remove the front seat belt assembly from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9055 1. Position the rear seat belt retractor/pretensioner assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body. Tighten the front seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft). 3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the front seat belt upper guide shoulder bolt trim cover. 6. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Front Seat Belt Replacement (Regular and Extended Cab) Front Seat Belt Replacement (Regular and Extended Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9056 2. Open the front seat belt upper guide shoulder bolt trim cover (4). 3. Remove the front seat belt upper guide shoulder bolt (5). 4. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). On extended cab models, the front seat belt retractor/pretensioner is located in the rear door, not the rear corner of the cab. 5. Remove the front seat belt anchor bolt (2). 6. Disconnect the electrical connector from the retractor/pretensioner (1). 7. Remove the bolt (3) that retains the seat belt retractor/pretensioner assembly to the body. 8. Remove the front seat belt assembly from the vehicle. Installation Procedure 1. Position the rear seat belt retractor/pretensioner assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9057 2. Install the bolt (3) which retains the seat belt retractor/pretensioner assembly (1) to the body. Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft). 3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper guide with the bolt (5). Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the front seat belt upper guide shoulder bolt trim cover (4). 6. Install the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Front Seat Center Belt Replacement Front Seat Center Belt Replacement Removal Procedure 1. Remove the rear inboard seat bolt (1) from the passenger seat. 2. Remove the grommet securing the center seat belt assembly (2) to the seat adjuster. 3. Remove the center seat belt assembly. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9058 1. Position the center seat belt assembly (2) over the rear inboard seat adjuster mounting hole. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the front seat mounting bolt (1). Tighten the front seat mounting bolt to 52.5 Nm (39 lb ft). Rear Seat Belt Replacement Rear Seat Belt Replacement Removal Procedure 1. Open the rear seat belt upper guide shoulder bolt trim cover. 2. Remove the rear seat belt upper guide shoulder bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9059 3. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Remove the rear seat belt anchor bolt. 5. Remove the bolt that retains the seat belt retractor assembly to the body. 6. Remove the rear seat belt assembly from the vehicle. Installation Procedure 1. Position the rear seat belt retractor assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the seat belt retractor assembly to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9060 Tighten the rear seat belt retractor bolt to 52.5 Nm (39 lb ft). 3. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the rear seat belt upper guide bolt to 52.5 Nm (39 lb ft). 4. Install the rear seat belt upper guide shoulder bolt trim cover. 5. Install the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 6. Install the rear seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the rear seat belt anchor bolt to 52.5 Nm (39 lb ft). Seat Belt Latch Stop Installation Seat Belt Latch Stop Installation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9061 Seat Belt Replacement - Center Rear (Crew Cab) Seat Belt Replacement - Center Rear (Crew Cab) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9062 1. Remove the rear seat shoulder belt guide cover. 2. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the bolt that retains the rear center seat belt assembly to the floor panel. 4. Remove the rear center seat belt assembly from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Replacement (Crew Cab) > Page 9063 1. Position the rear center seat belt assembly on the floor panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the rear center seat belt assembly to the floor. Tighten the rear center seat belt bolt to 52.5 Nm (39 lb ft). 3. Route the rear center seat belt webbing up through the guide loop. Ensure that the seat belt webbing is not twisted. 4. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Install the rear seat shoulder belt guide cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 9072 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 07-09-41-010D > May > 10 > Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: Customer Interest Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 9082 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-41-010D > May > 10 > Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 9096 Seat Belt Buckle: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 Seat Belt Buckle - Passenger X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 9097 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Replacement (Crew Cab) Rear Seat Belt Buckle Replacement (Crew Cab) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Rear Bench Seat Replacement). 2. Remove the grommet securing the rear seat belt buckle assembly to the seat. 3. Remove the rear seat belt buckle assembly from the seat cushion. Installation Procedure 1. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Rear Bench Seat Replacement). Do not install the rear bench seat mounting nut. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9100 2. Install the rear seat belt buckle through the seat cushion loop and position the seat belt buckle assembly over the rear bench seat mounting hole. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear bench seat mounting nut. Tighten the rear bench seat mounting nut to 52.5 Nm (39 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9101 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Replacement (Extended Cab) Rear Seat Belt Buckle Replacement (Extended Cab) Removal Procedure 1. Remove the rear folding seat from the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Body and Frame/Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 2. Remove the rear seat belt buckle assembly (1) from the vehicle. Installation Procedure 1. Position the rear seat belt buckle assembly (1) in the vehicle under the inboard leg (2) of the rear folding seat. 2. Install the rear folding seat in the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Body and Frame/Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9102 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Center Front Seat Belt Buckle Replacement - Center Front Removal Procedure 1. Remove the rear inboard seat bolt from the driver seat. 2. Remove the grommet securing the center seat belt buckle assembly (1) to the seat adjuster. 3. Remove the center seat belt buckle assembly (1). Installation Procedure 1. Position the seat belt buckle assembly (1) over the rear inboard seat adjuster mounting hole. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9103 2. Install the front seat mounting bolt (2). Tighten the front seat mounting bolt to 52.5 Nm (39 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9104 Seat Belt Buckle: Service and Repair Driver or Passenger Seat Belt Buckle Replacement Driver or Passenger Seat Belt Buckle Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). 2. Disconnect the seat belt buckle electrical connector (1). 3. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 4. Pull the seat belt buckle assembly (1) out though the opening in the seat cushion. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Replacement (Crew Cab) > Page 9105 1. Install the seat belt buckle assembly (1) through the seat cushion pad. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2). Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft). 3. Connect the seat belt buckle electrical connector (1). 4. Install the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) Removal Procedure 1. Open the front seat belt upper guide shoulder bolt trim cover. 2. Remove the front seat belt upper guide shoulder bolt. 3. Remove the knob (2) from the front seat belt shoulder adjuster (3). 4. Remove the upper center pillar trim panel (1). Refer to Center Pillar Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Remove the 2 bolts securing the adjuster to the vehicle. 6. Remove the front seat belt shoulder adjuster from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9114 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the 2 bolts securing the front seat belt shoulder adjuster (3) to the vehicle. Tighten the front seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft). 2. Install the upper center pillar trim panel (1). Refer to Center Pillar Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Install the knob (2) on the front seat belt shoulder adjuster (3). 4. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the front seat belt upper guide shoulder bolt trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9115 Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Extended Cab) Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Extended Cab) Removal Procedure 1. Remove the knob (2) from the front seat belt shoulder adjuster (1). 2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt upper guide shoulder bolt. 4. Remove the rear side access door upper trim panel (3). 5. Remove the 2 bolts securing the adjuster to the vehicle. 6. Remove the front seat belt shoulder adjuster from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9116 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the 2 bolts securing the front seat belt shoulder adjuster (1) to the vehicle. Tighten the front seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft). 2. Install the rear side access door upper trim panel (3). 3. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 4. Install the front seat belt upper guide shoulder bolt trim cover. 5. Install the knob (2) on the front seat belt shoulder adjuster (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9117 Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Regular Cab) Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Regular Cab) Removal Procedure 1. Open the front seat belt upper guide shoulder bolt trim cover. 2. Remove the front seat belt upper guide shoulder bolt. 3. Remove the knob (2) from the front seat belt shoulder adjuster (1). 4. Remove the body rear corner upper trim panel (3). Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Remove the 2 bolts securing the adjuster to the vehicle. 6. Remove the front seat belt shoulder adjuster from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9118 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the 2 bolts securing the front seat belt shoulder adjuster (1) to the vehicle. Tighten the front seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft). 2. Install the body rear corner upper trim panel (3). Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Install the knob (2) on the front seat belt shoulder adjuster (1). 4. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the front seat belt upper guide shoulder bolt trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9119 Seat Belt Guide Track: Service and Repair Rear Seat Shoulder Belt Guide Adjuster Replacement Rear Seat Shoulder Belt Guide Adjuster Replacement Removal Procedure 1. Open the rear seat belt upper guide shoulder bolt trim cover. 2. Remove the rear seat belt upper guide shoulder bolt. 3. Remove the knob from the rear seat belt shoulder adjuster (1). 4. Remove the body rear corner upper trim panel (2). Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Remove the 2 bolts securing the adjuster to the vehicle. 6. Remove the rear seat belt shoulder adjuster from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement (Crew Cab) > Page 9120 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the 2 bolts securing the rear seat belt shoulder adjuster (1) to the vehicle. Tighten the rear seat belt shoulder adjuster bolts to 52.5 Nm (39 lb ft). 2. Install the body rear corner upper trim panel (2). Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Install the knob on the rear seat belt shoulder adjuster (1). 4. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the rear seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the rear seat belt upper guide shoulder bolt trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 9125 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 9126 Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tension Sensor > Component Information > Locations Seat Belt Tension Sensor: Locations Passenger Compartment/Roof Component Views Passenger Seat Components - 1 of 2 1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams Component Connector End Views Seat Belt Pretensioner - Driver Seat Belt Pretensioner - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 9133 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures Seat Belt Tensioner: Procedures Pretensioner Handling and Scrapping Warning When carrying an undeployed inflatable restraint seat belt retractor pretensioner: * Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped. * Carry the seat belt pretensioner by the housing, keeping hands and fingers away from the seat belt webbing. * Make sure the opening, from which the seat belt webbing extends, faces downward and the seat belt webbing hangs freely. Failure to observe these guidelines may result in personal injury. Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt retractor pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt retractor pretensioner in the following situations: * After replacement of a seat belt retractor pretensioner under warranty. The seat belt retractor pretensioner may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner. * If the vehicle is involved in a campaign affecting the seat belt retractor pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Inside the Vehicle Refer to Inflator Module Handling and Scrapping (See: Air Bag Systems/Air Bag/Service and Repair) for deploying the pretensioner inside vehicle under Vehicle Scrapping Procedure. Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning. * The seat belt pretensioner pigtail, if equipped, is damaged. * The seat belt retractor pretensioner connector is damaged. * The seat belt retractor pretensioner connector terminals are damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. Warning In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. Special Tools * J 38826 SIR Deployment Harness * J 38826-25 for seat belt pretensioner module adapter * J 39401-B SIR Deployment Fixture * An appropriate pigtail adaptor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9136 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt retractor pretensioner from the vehicle. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab)). 5. When carrying a seat belt retractor pretensioner to the deployment area, keep fingers clear of the seat belt webbing. 6. Clear a space on the ground about 1.85 m (6 ft) in diameter (a) for deployment of the seat belt pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9137 10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method. * Adjust and secure the J 39401-B arms (4) to the deployment fixture, with the short slotted portions of the arms standing vertically and facing toward the center of the deployment fixture. * To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt pretensioner (1) to the deployment fixture brackets. * Securely tighten all fasteners prior to deployment. 11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9138 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the seat belt pretensioner connector to the adapter on the deployment harness. Note: When deploying a seat belt retractor pretensioner, the rapid expansion of gas is very loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed. 16. Clear the area of people. 17. Separate the 2 banana plugs on the SIR deployment harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9139 Note: When the seat belt retractor pretensioner deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the rapid expansion of gas inside the pretensioner. 18. Place a 12 V minimum/2 A minimum power source, such as a vehicle battery, near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the seat belt retractor pretensioner deploys. 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the seat belt retractor pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt retractor pretensioner as soon as possible. 25. Dispose of the deployed seat belt retractor pretensioner through normal refuse channels. 26. Wash hands with a mild soap. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9140 Seat Belt Tensioner: Removal and Replacement Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt upper guide shoulder bolt. 4. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9141 5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly to the body. 8. Remove the front seat belt assembly from the vehicle. Installation Procedure 1. Position the rear seat belt retractor/pretensioner assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body. Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft). 3. Connect the electrical connector to the retractor/pretensioner. 4. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9142 Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the front seat belt upper guide shoulder bolt trim cover. 6. Install the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 7. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9143 2. Open the belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt upper guide shoulder bolt. 4. Remove the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Remove the seat belt anchor bolt. 6. Disconnect the electrical connector from the retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly to the body. 8. Remove the seat belt assembly from the vehicle. Installation Procedure 1. Position the seat belt retractor/pretensioner assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9144 2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body. Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft). 3. Connect the electrical connector to the retractor/pretensioner. 4. Install the seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the seat belt upper guide bolt to 52.5 Nm (39 lb ft). 5. Install the seat belt upper guide shoulder bolt trim cover. 6. Install the seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft). 7. Install the body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Open the front seat belt upper guide shoulder bolt trim cover. 3. Remove the front seat belt upper guide shoulder bolt. 4. Remove the lower center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Remove the front seat belt anchor bolt. 6. Disconnect the electrical connector from the retractor/pretensioner. 7. Remove the bolt that retains the seat belt retractor/pretensioner assembly to the body. 8. Remove the front seat belt assembly from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 9145 1. Position the rear seat belt retractor/pretensioner assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt which retains the seat belt retractor/pretensioner assembly to the body. Tighten the seat belt retractor/pretensioner bolt to 52.5 Nm (39 lb ft). 3. Connect the electrical connector to the retractor/pretensioner. 4. Install the lower center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 5. Install the front seat belt anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt anchor bolt to 52.5 Nm (39 lb ft). 6. Install the front seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten the front seat belt upper guide bolt to 52.5 Nm (39 lb ft). 7. Install the front seat belt upper guide shoulder bolt trim cover. 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views Impact Sensor: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 9151 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 9152 Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 9153 Impact Sensor: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 9154 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Door Component Views > Page 9155 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9156 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9157 Inflatable Restraint Passenger Presence System (PPS) Sensor Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9158 Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 3. Loosen the fasteners (1) retaining the front discriminating sensors to the radiator support. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9161 4. Remove the sensor assembly from the radiator support. 5. Position the sensor assembly, to gain access to the electrical connector. 6. Remove the connector-position assurance (CPA) from the sensor electrical connector. 7. Disconnect the sensor electrical connector. 8. Remove the sensor from the vehicle. Installation Procedure 1. Remove any dirt, grease, or other impurities from the mounting surfaces. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9162 2. Position the sensor near the radiator support. 3. Connect the sensor electrical connector. 4. Install the CPA to the sensor electrical connector. 5. Install the sensor assembly to the radiator support. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9163 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the 2 fasteners (1) retaining the discriminating sensor assembly to the radiator support. Tighten the bolts to 9 Nm (80 lb in). 7. Install the grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 8. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9164 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Removal Procedure Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). 2. Fold back the carpet in order to gain access to the sensor. Refer to Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 3. Disconnect the electrical connector. 4. Remove the nuts securing the rollover sensor to the floor panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9165 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the nuts securing the rollover sensor to the floor panel. Tighten the screws to 10 Nm (88 lb in). 2. Connect the electrical connectors. 3. Install the carpet. Refer to Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair). 4. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9166 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Removal Procedure Warning Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor to the door. 5. Disconnect the impact sensor electrical connector from the side impact sensor. 6. Remove the side impact sensor from the door. Installation Procedure 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 9167 2. Position the side impact sensor horizontally to the door. 3. Connect the electrical connector to the side impact sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screws which retain the side impact sensor to the door. Tighten the screws to 9 Nm (79 lb in). 5. Fully seat the water deflector to the door. 6. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 7. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Locations Seat Belt Tension Sensor: Locations Passenger Compartment/Roof Component Views Passenger Seat Components - 1 of 2 1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 9175 Seat Occupant Sensor: Locations Passenger Compartment/Roof Component Views Passenger Seat Components - 2 of 2 1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 9176 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Removal Procedure Warning Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 1. Remove the seat cushion trim cover and pad. 2. Disconnect the electrical connectors. 3. Remove the bolts that retain the electronic control unit (ECU) (1) from the bottom of the passenger seat cushion frame. 4. Remove the pressure switch (2) from the bottom of the passenger seat cushion frame. 5. Remove the push-in retainers (1) that hold the bladder to the seat cushion frame. 6. Remove the inflatable restraint passenger presence system from the seat. Installation Procedures 1. Install the inflatable restraint passenger presence system to the seat. 2. Install the push-in retainers (1) that hold the bladder to the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 9177 3. Install the pressure sensor (2) to the bottom of the passenger seat cushion frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolts that retain the ECU (1) to the bottom the passenger seat cushion frame. Tighten the bolts to 2 Nm (18 lb in). 5. Connect the electrical connectors. 6. Install the seat cushion trim cover and pad. 7. Re-zero the inflatable restraint passenger presence system. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Passenger Seat Components - 1 of 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 9181 1 - Inflatable Restraint Seat Belt Tension Sensor - Passenger 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger Under the Passenger Seat Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 9182 1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger (KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1) 7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 9183 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Left Inflatable Restraint Seat Position Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 9184 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement (Power Seat) Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). 2. Ensure that the seat is in the full rear position. 3. Locate the seat position sensor (1) under the seat on the inside of the inner seat rail. 4. Disconnect the electrical connector (3) from the seat position sensor (1). 5. Remove the 2 nuts (2) that retain the seat position sensor to the seat rail. 6. Remove the seat position sensor from the seat. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 9185 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the seat position sensor (1) to the seat rail with 2 nuts (2). Tighten the seat position sensor nuts to 9 Nm (79 lb in). 2. Connect the electrical connector (13) to the seat position sensor (1). 3. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Body and Frame/Seats/Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna Antenna Mast: Technical Service Bulletins Audio System - Difficult To Install Fixed Radio Antenna INFORMATION Bulletin No.: 07-08-44-001F Date: June 15, 2010 Subject: Information on Difficult to Install Fixed Radio Antenna Mast Models: 2006-2011 Cadillac Escalade EXT 2005-2010 Chevrolet Cobalt 2006-2009 Chevrolet TrailBlazer Models 2006-2011 Chevrolet Avalanche, Colorado, Silverado (Classic and New Style) 2006-2009 GMC Envoy 2006-2011 GMC Canyon, Sierra (Classic and New Style) 2006-2010 Pontiac G5 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years, a graphic with accompanying text and additional text in the Parts Information Description. Please discard Corporate Bulletin Number 07-08-44-001E (Section 08 - Body and Accessories). - A design change was made to the antenna base and antenna mast starting in October 2005. The radio antenna base size increased from 6 mm (0.23 in) to 7 mm (0.27 in) for improved stability and radio reception. - There are two different design antenna masts available. The antenna masts can be distinguished by the outer bottom of the antenna mast. The first design antenna mast (1) will have a six-sided hex design and a 6 mm (0.23 in) inside diameter thread. The second design antenna mast (2) will have two flats on the outer mast and a 7 mm (0.27 in) inside diameter thread. - The second design antenna mast will have more resistance when installing due to the interference fit of the threads in the mast as identified by the arrows in the graphic. Note Before proceeding, verify that the mast and base stud are properly aligned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna > Page 9195 - A wrench will be needed to install the antenna mast. When starting to thread the antenna mast onto the base stud, interference will be felt. The interference is similar to the feeling of a cross threaded fastener. Important Use a protective tape or a cloth inside an adjustable wrench when installing the antenna mast. This will help prevent damage to the painted coating on the antenna mast. - Tighten the antenna mast. Tighten Tighten to 6 Nm (53 lb in). Parts Information Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Page 9196 Antenna Mast: Service and Repair Fixed Antenna Mast Replacement Removal Procedure 1. Use the tool (1) provided with the vehicle to unscrew the antenna mast. 2. Remove the antenna mast from the antenna base. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Page 9197 1. Install the antenna mast to the antenna base. Important: Install the antenna mast using the mast tool. Ensure the antenna mast is fully seated to the antenna base. 2. Using the mast tool, tighten the antenna mast (1) until fully seated to the antenna base (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair Antenna, Navigation: Service and Repair Cellular and Navigation Antenna Assembly Replacement Removal Procedure 1. Lower the front portion of the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Disconnect the electrical connectors from the antenna assembly. 3. Loosen the retaining nut until the assembly can be removed from the roof panel. 4. Using an upward motion, remove the antenna assembly from the roof. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Page 9201 1. Install the antenna assembly from the top of the roof. 2. Lower the antenna assembly to the roof panel, ensuring the anti-rotation pin is properly indexed. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the retaining nut. Tighten the nut to 6 Nm (53 lb in). 4. Connect the antenna electrical connectors. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement Antenna, Phone: Service and Repair Cellular Communications/Digital Radio Antenna Replacement Cellular Communications/Digital Radio Antenna Replacement Removal Procedure 1. Lower the front portion of the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Disconnect the electrical connectors from the digital radio antenna assembly. 3. Remove the retaining bolt and retainer from the antenna. 4. Squeeze the plastic retainer to release the antenna assembly from the roof panel. 5. Using an upward motion, remove the antenna assembly from the roof. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9206 1. Install the antenna assembly to the top of the roof. 2. Lower the antenna assembly to the roof panel, ensuring the anti-rotation pin is properly indexed. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the retainer and retainer bolt. Tighten the bolt to 6 Nm (53 lb in). 4. Connect the antenna electrical connectors. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9207 Antenna, Phone: Service and Repair Cellular and Navigation Antenna Assembly Replacement Cellular and Navigation Antenna Assembly Replacement Removal Procedure 1. Lower the front portion of the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Disconnect the electrical connectors from the antenna assembly. 3. Loosen the retaining nut until the assembly can be removed from the roof panel. 4. Using an upward motion, remove the antenna assembly from the roof. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9208 1. Install the antenna assembly from the top of the roof. 2. Lower the antenna assembly to the roof panel, ensuring the anti-rotation pin is properly indexed. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the retaining nut. Tighten the nut to 6 Nm (53 lb in). 4. Connect the antenna electrical connectors. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair > Cellular Communications/Digital Radio Antenna Replacement > Page 9209 Antenna, Phone: Service and Repair Mobile Telephone Digital Antenna Replacement Mobile Telephone Digital Antenna Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement Radio Antenna Cable Extension Cable Replacement Removal Procedure 1. Remove the accessory trim panel. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the radio. Refer to Radio Replacement (See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 3. Lower the instrument panel (I/P) compartment door to a full down position. 4. Disconnect the radio extension antenna cable (1). 5. Remove the clip retaining the extension cable. 6. Remove the cable from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9215 1. Install the cable to the vehicle. 2. Install the clip retaining the extension cable. 3. Connect the radio extension antenna cable (1). 4. Close the I/P compartment door. 5. Install the radio. Refer to Radio Replacement (See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Replacement). 6. Install the accessory trim panel. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9216 Antenna Cable: Service and Repair Digital Radio Antenna Cable Replacement Digital Radio Antenna Cable Replacement Removal Procedure 1. If the vehicle is equipped with OnStar(R) refer to Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1) (See: Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1))Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1, U2K) (See: Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1, U2K)). 2. Lower the front portion of the headliner to reveal the digital radio antenna connectors. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 3. Disconnect the digital radio antenna connectors (1). 4. Detach the 2 upper coax cable retainers from the header panel. 5. Detach the 3 coax cable retainers from the windshield pillar. 6. Lower the instrument panel (I/P) compartment door to a full down position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9217 7. Disconnect the digital receiver extension cable (1) from the receiver. 8. Remove the retainers (2) from the I/P. 9. Disconnect the electrical connector (3). 10. Remove the extension cable from the vehicle. 11. Detach the coax cable retainer (3) from the I/P. 12. Attach a mechanics wire to the end of the coax cable (2). 13. Detach the coax cable retainer (4) from the hinge pillar. 14. Grasp the cable (1) and pull upward to release the retainer from the hinge pillar. 15. Pull upward to remove the cable from behind the I/P. 16. Remove the cable from the vehicle leaving the mechanics wire behind the I/P. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9218 1. Attach the existing mechanics wire to the end of the coax cable (2). 2. Pull downward on the mechanics wire to install the cable behind the I/P. 3. Attach the coax cable retainer (4) to the hinge pillar. 4. Attach the coax cable retainer (3) to the I/P. 5. Connect the digital receiver extension cable (1) to the receiver. 6. Attach the retainers (2) to the I/P. 7. Connect the electrical connector (3). 8. Close the (I/P) compartment door. 9. Attach the 3 coax cable retainers to the windshield pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9219 10. Connect the digital radio antenna connectors (1). 11. Attach the 2 upper coax cable retainers to the header panel. 12. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9220 Antenna Cable: Service and Repair Antenna Cable Replacement Antenna Cable Replacement Removal Procedure 1. Remove the right front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair). 2. Remove the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement Left Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the instrument panel (I/P) compartment door. Refer to Instrument Panel Compartment Door Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair). 4. Disconnect the radio antenna cable (1) from the extension cable. 5. Remove the grommet from the hinge pillar in an outbound direction. 6. Attach a mechanics wire to the to the antenna cable (1). 7. Remove the antenna mast. Refer to Fixed Antenna Mast Replacement (See: Antenna Mast/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9221 8. Remove the screws retaining the antenna base. 9. Remove the grommet (1) and cable from the routing hole. 10. Remove the antenna cable from the vehicle. 11. Leave the mechanics wire in place for assembly purposes. Installation Procedure 1. Attach the mechanics wire to the end of the antenna cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9222 2. Pull on the mechanics wire to route the cable and grommet (1) through the hinge pillar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screws retaining the antenna base. Tighten the screws to 7.5 Nm (66 lb in). 4. Install the antenna mast. Refer to Fixed Antenna Mast Replacement (See: Antenna Mast/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9223 5. Remove the mechanics wire from the antenna cable (1). 6. Install the grommet to the hinge pillar. 7. Connect the radio antenna cable (1) to the extension cable. 8. Install the I/P compartment door. Refer to Instrument Panel Compartment Door Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair). 9. Install the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair). 10. Install the right front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9224 Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1) Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1) Removal Procedure 1. Lower the front portion of the headliner to reveal the coax cable leading to the navigation and cellular telephone antenna connectors (1). Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Disconnect the coax cable connectors (1). 3. Detach the fasteners retaining the coax cable to the header panel. 4. Detach the 3 coax cable retainers from the windshield pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9225 5. Open the instrument panel (I/P) compartment door to a full down position. 6. Disconnect the antenna coax cable (2) from the vehicle communication interface module (VCIM) jumper harness. 7. Detach the retainers from the I/P structure. 8. Attach a mechanics wire to the end of the coax cable (2). 9. Detach the coax cable retainer (4) from the hinge pillar. 10. Grasp the cable (1) and gently pull upward to release the retainer (5) from the hinge pillar. 11. Continue pulling the cable upward to remove the cable from behind the I/P. 12. Remove the cable from the vehicle leaving the mechanics wire routed behind the I/P. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9226 1. Attach a mechanics wire to the end of the coax cable (1). 2. Carefully remove the coax cable retainer (4) from the cable. 3. Grasp the mechanics wire and gently pull downward to route the cable behind the I/P. 4. Attach the retainer (4) to the hinge pillar. 5. Attach the remaining lower retainers to the I/P structure. 6. Connect the antenna coax cable (2) to the VCIM jumper harness. 7. Close the I/P compartment door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9227 8. Attach the 3 coax cable retainers to the windshield pillar. 9. Attach the fasteners retaining the coax cable to the header panel. 10. Connect the coax cable connectors (1). 11. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9228 Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1, U2K) Mobile Telephone and Navigation Antenna Coaxial Cable Replacement (UE1, U2K) Removal Procedure 1. Lower the front portion of the headliner to reveal the coax cables and wiring harness assembly. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Disconnect the connectors to the navigation cellular telephone antenna (1). 3. Detach the fasteners retaining the coax cable to the header panel. 4. Disconnect the connectors to the digital radio antenna (2). 5. Detach the 3 coax cable retainers from the windshield pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9229 6. Open the instrument panel (I/P) compartment door to a full down position. 7. Disconnect the connector (2) from the vehicle communication interface module (VCIM) jumper harness. 8. Disconnect the connector (1) from the digital radio receiver jumper harness. 9. Detach the retainer (3) from the I/P structure. 10. Attach a mechanics wire to the end of the coax cable (1) and (2). 11. Detach the coax cable retainer (4) from the hinge pillar. 12. Grasp the cable above the I/P and gently pull upward to release the retainer (5) from the hinge pillar. 13. Continue pulling the cable upward to remove the cable from behind the I/P. 14. Remove the cable from the vehicle leaving the mechanics wire routed behind the I/P. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9230 1. Attach a mechanics wire to the end of the coax cable (1) and (2). 2. Carefully remove the coax cable retainer (4) from the cable. 3. Grasp the mechanics wire and gently pull downward to route the cable behind the I/P. 4. Attach the retainer (4) to the hinge pillar. 5. Attach the remaining lower retainers to the I/P structure. 6. Install the connectors (2) to the VCIM jumper harness. 7. Install the connectors (1) to the digital radio receiver jumper harness. 8. Close the I/P compartment door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement > Page 9231 9. Attach the 3 coax cable retainers to the windshield pillar. 10. Install the connectors to the digital radio antenna (2). 11. Attach the fasteners retaining the coax cable to the header panel. 12. Install the coax cable connectors (1). 13. Install the headliner. Refer to Headlining Trim Panel Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair Transmitter Programming Important: Up to 4 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. The order in which the transmitters are programmed is important. The first transmitter programmed will be transmitter #1, and the second transmitter programmed will be transmitter #2. Use care to program the transmitters correctly. Important: All key fobs must be programmed each time any one fob is programmed. The scan tool must stay connected until all of the transmitters are programmed. 1. Install a scan tool and navigate to the BCM Module Setup menu. 2. Select Program Key Fobs. 3. Follow the scan tool on-screen directions. 4. When the programming operations have completed, operate the transmitter functions to verify correct system operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Service and Repair Cellular Phone Microphone: Service and Repair Mobile Telephone Microphone Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9252 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9253 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9254 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update Communications Control Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update > Page 9260 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9266 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9271 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9272 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9273 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9278 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9283 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9289 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9294 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9299 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9305 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9306 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9307 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9312 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9317 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 9318 Communications Control Module: Diagrams Component Connector End Views Vehicle Communications Interface Module (VCIM) X1 Vehicle Communications Interface Module (VCIM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 9319 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 9320 Communications Control Module: Service and Repair Communication Interface Module Replacement Removal Procedure Note: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Ensure the ignition switch is in the OFF position. 2. Remove the service panel located on the right side of the instrument panel (I/P). 3. Disconnect the VCIM electrical connectors as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 9321 4. Remove the screw retaining the VCIM to the bracket. 5. Release the tab (1) on the bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 9322 6. Remove the VCIM from the bracket. 7. Remove the VCIM from the vehicle. Installation Procedure 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 9323 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VCIM to the bracket ensuring the retaining tab (1) is fully seated. Tighten the screw fully driven , seated and not stripped. 3. Connect the VCIM electrical connectors as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 9324 4. Install the service panel. Note: After replacing the VCIM, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 5. Reconfigure the OnStar(R) system. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 6. When replacing the communication interface module be sure to transfer Bluetooth Antenna, if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views Central Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Below the I/P Components - 1 of 2 1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 9329 Central Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 9330 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation Driver Information Center (DIC) The driver information center (DIC) consists of a double line 14 character display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using a control stem. Pressing the stem for 1 second will display the DIC options. Pressing the stem for more than 2 seconds will select an option. DIC Displays The driver information center (DIC) parameters are displayed by order of priority as follows (from highest to lowest) : * Service Diagnostics * Feature Programming * Driver Warnings * Vehicle Information Vehicle Information Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance or related information. When the English/Metric status changes, any applicable vehicle information data values will also change. Odometer The odometer is capable of displaying values from 0-999,999 KM or MI. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip/reset switch. The odometer will remain displayed for 5 seconds. Trip Odometers The trip odometer is capable of displaying values from 0-9999.9 KM or MI. When the maximum value is reached, the trip odometer will roll over to 0.0. Holding the control stem for greater than 4 seconds while the trip odometer is displayed will reset the displayed trip odometer to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. Engine Oil Life Engine Oil Life percentage values are based on serial data messages to the instrument panel cluster (IPC). The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0 to 100%. Pressing the control stem for longer than 2 seconds while Engine Oil Life is displayed on the DIC will reset the value to 100%. An audible warning will sound confirming that the system has been reset. Display appears as OIL LIFE: XXX%. Display Language The driver information center (DIC) is capable of displaying messages in more than one language. The DIC language selection procedure is as follows: 1. With the engine OFF, turn the key to ON, but do not start the engine. 2. Close all doors so the DOORS message does not display in the DIC. 3. Momentarily press and release the trip reset stem until the current language is displayed: English, French or Spanish. 4. To select a different language, press and hold the trip reset stem until the next language appears. 5. Repeat Step 4 until the desired language is displayed. Once the desired language is shown on the DIC display, the language is set. 6. To exit language selection, momentarily press and release the trip stem. All DIC messages will now display in the language selected. Feature Programming Refer to Personalization Description and Operation (See: Description and Operation/Personalization Description and Operation). Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message Description and Operation). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9342 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9348 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Global Positioning System Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9375 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Global Positioning System Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9381 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update Navigation Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) Generation 8.0L Software Update > Page 9391 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Navigation Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9397 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck Seat Track: All Technical Service Bulletins Interior - Front Manual Seat(s) Won't Adjust, Stuck TECHNICAL Bulletin No.: 10-08-50-006 Date: June 02, 2010 Subject: Front Manual Seat(s) Won't Adjust Forward or Rearward, Sticks or Binds (Install Revised Seat Adjuster Bar, Replace Seat Adjuster) Models: 2004-2010 Chevrolet Colorado 2004-2010 GMC Canyon with Seat RPO AM6 or AR9 Condition Some customers may comment that the front seat(s) appear to be stuck in position and they are unable to move the seat forward or rearward in the vehicle. Cause This condition may be caused by the seat adjuster bar (handle) bending or coming out of position. This may also cause damage to the plastic adjuster blocks located in the seat adjuster assembly. Seat tracks (adjuster assemblies) that are not parallel to each other may contribute to the development of this condition. Correction Use the following procedure to repair the affected seat(s). 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement in SI. 2. Locate the adjuster bar (handle). Determine if the handle pin(s) have come out of the plastic adjuster block(s). 3. If the pin is in the block, inspect the gap between the adjuster bar and the plastic adjuster blocks. There should be no space between the two components. 4. If the pin(s) are out of the block(s) or there is a gap, the adjuster bar needs to be replaced with the revised part listed below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9403 5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front. 7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any damage where the adjuster bar engages into the holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement in SI for replacement procedures. 8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends of the bar, it may bend at the pivot mount holes. Ensure that the curved portion of the bar is in the upward position. 9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard adjuster blocks. Ensure that there is no gap between the two components. 10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement in SI. 11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat adjuster function. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9404 Warranty Information For vehicles repaired under warranty, use: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9410 5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front. 7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any damage where the adjuster bar engages into the holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement in SI for replacement procedures. 8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends of the bar, it may bend at the pivot mount holes. Ensure that the curved portion of the bar is in the upward position. 9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard adjuster blocks. Ensure that there is no gap between the two components. 10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement in SI. 11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat adjuster function. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 9411 Warranty Information For vehicles repaired under warranty, use: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Service and Repair Compact Disc Player (CD): Service and Repair Compact Disc Care and Cleaning Care of CDs Handle CDs carefully. Store them in their original cases or other protective cases and away from direct sunlight and dust. The CD player scans the bottom surface of the disc. If the surface of a CD is damaged, such as cracked, broken, scratched, or wrinkled labeling, the CD will not play properly or not at all. If the surface of a CD is soiled, take a soft, lint free cloth or dampen a clean, soft cloth in a mild, neutral detergent solution mixed with water, and clean it. Make sure the wiping process starts from the center to the edge. Do not touch the bottom side of a CD while handling it. This could damage the surface. Pick up CDs by grasping the outer edges or the edge of the hole and the outer edge. Care of the CD Player The use of CD lens cleaners for CD players is not advised, due to the risk of contaminating the internal lens of the CD optics with lubricants. Stuck CDs Interrupting the battery power by pulling the fuse will sometimes release a stuck CD. If a CD is stuck, and removed, inspect it for warps, cracks, etc. If the CD is damaged, do not replace the radio. Labeling CDs Paper labels can eventually warp and wrinkle, and this will cause the disc to jam inside the CD player. Try labeling the top of the discs with a soft magic marker instead. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Diagrams Radio Receiver: Diagrams Component Connector End Views Digital Radio Receiver (U2K) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 9428 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 9434 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Component Connector End Views Speaker - Left Front Speaker - Left Front Tweeter (UQ2) Speaker - Left Rear (Extended/Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 9442 Speaker - Right Front Speaker - Right Front Tweeter (UQ2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 9443 Speaker - Right Rear (Extended/Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Replacement Speaker: Service and Repair Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Remove the screw securing the speaker to the door. 3. Remove the speaker and the two tabs from the slots in the door. 4. Disconnect the speaker electrical connector. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 9446 1. Connect the speaker electrical connection. 2. Install the two tabs on the speaker into the slots in the door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw securing the speaker to the door. Tighten the front door speaker screw to 2.5 Nm (22 lb in). 4. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 9447 Speaker: Service and Repair Radio Rear Side Door Speaker Replacement Radio Rear Side Door Speaker Replacement Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 2. Remove the screw securing the speaker to the door. 3. Remove the speaker and the two tabs from the slots in the door. 4. Disconnect the speaker electrical connector. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 9448 1. Connect the speaker electrical connection. 2. Install the two tabs on the speaker into the slots in the door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw securing the speaker to the door. Tighten the rear door speaker screw to 2.5 Nm (22 lb in). 4. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views Central Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Below the I/P Components - 1 of 2 1 - Vehicle Communication Interface Module (VCIM) X1 (UE1) 2 - Vehicle Communication Interface Module (VCIM) X2 (UE1) 3 - Vehicle Communication Interface Module (VCIM) (UE1) 4 - I/P Courtesy Lamp - Right 5 - I/P Courtesy Lamp - Left 6 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 9460 Central Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 9461 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9470 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9471 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9472 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9478 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9484 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9489 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9490 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9491 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9496 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9501 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Communications Control Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9507 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9512 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9517 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9523 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9524 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 9525 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 9530 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 9535 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9536 Communications Control Module: Diagrams Component Connector End Views Vehicle Communications Interface Module (VCIM) X1 Vehicle Communications Interface Module (VCIM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9537 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9538 Communications Control Module: Service and Repair Communication Interface Module Replacement Removal Procedure Note: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Ensure the ignition switch is in the OFF position. 2. Remove the service panel located on the right side of the instrument panel (I/P). 3. Disconnect the VCIM electrical connectors as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9539 4. Remove the screw retaining the VCIM to the bracket. 5. Release the tab (1) on the bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9540 6. Remove the VCIM from the bracket. 7. Remove the VCIM from the vehicle. Installation Procedure 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9541 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VCIM to the bracket ensuring the retaining tab (1) is fully seated. Tighten the screw fully driven , seated and not stripped. 3. Connect the VCIM electrical connectors as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 9542 4. Install the service panel. Note: After replacing the VCIM, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 5. Reconfigure the OnStar(R) system. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 6. When replacing the communication interface module be sure to transfer Bluetooth Antenna, if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9551 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9557 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Global Positioning System Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9583 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Global Positioning System Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9589 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Navigation Module: Customer Interest OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9598 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update Navigation Module: All Technical Service Bulletins OnStar(R) - Generation 8.0L Software Update TECHNICAL Bulletin No.: 08-08-46-008C Date: January 25, 2011 Subject: OnStar(R) Generation 8.0L Software Update - Corrections For No LED, No Button Response, No Power, Battery Drain, Bluetooth Pairing, No Nametags, Remote Functions, Turn By Turn Routing, Turn By Turn Display, No OnStar(R) Hands Free Calling, No GPS, Advisor Record Feature and Automatic Crash Notification Repeat Calls (Reprogram OnStar(R) Module) Models: 2009 Buick Allure (Canada Only), LaCrosse, Lucerne 2009 Cadillac DTS 2009 Chevrolet Colorado, Impala, Malibu, TrailBlazer 2009 GMC Envoy, Canyon 2009 Pontiac G6 2009 HUMMER H2, H3 2009 Saturn AURA 2009 Saab 9-7X All Vehicles Equipped with OnStar(R) (RPO UE1) Attention: This bulletin is being issued to provide the dealer with information regarding a condition pertaining to certain OnStar(R) Generation 8.0L Vehicle Communication Interface Modules (VCIM) that affect the LED, button response, vehicle starting, Bluetooth(R) pairing, nametags, inability to perform certain remote functions, loss of turn-by-turn routing, turn-by-turn display, OnStar(R) hands-free calling, GPS, advisor record feature and automatic crash notification calls to OnStar(R). Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 08-08-46-008B (Section 08 - Body and Accessories). Condition Note Performing this procedure will clear out all of the customers nametags stored in the VCIM. These will need to be restored by the customer once the procedures are completed. Some customers on certain 2009 model year vehicles equipped with a Generation 8.0L OnStar system may report some of the following concerns: - No OnStar(R) LED and no response to any OnStar(R) buttons. Additionally, some customers may also have a battery drain. - Phone pairing feature for the Bluetooth(R) system is not retained after an ignition cycle. - Nametags for OHFC, Bluetooth(R) and Turn-by-Turn will be lost after an ignition cycle, or the nametag may be present but the customer is unable to use it or delete it. - The customer may request to be enrolled in the Verizon Family share (OnStar(R) Share Minutes) plan but when trying to use OHFC they receive a message that there are insufficient units. - OnStar(R) is unable to connect to the vehicle to perform remote functions (i.e. door unlock, horn honk, light flash). - Loss of Turn-by-Turn routing information. Some customers may be told by the OnStar(R) advisor that Turn-by-Turn is unavailable. Also, some customers may not have Turn-by-Turn display information in their vehicle. - The "Virtual Advisor" command may not be available or will not access the system for eNav routes that have been stored through MapQuest(R). - In rare cases, following a collision with an airbag deployment, the vehicle will make repeated calls to the OnStar(R) center. - No GPS location when calling into OnStar(R). - Unable to access the Advisor Record feature. Cause These conditions may be the result of a software anomaly within the OnStar(R) VCIM and can be corrected through a software update using the Service Programming System (SPS) application. Correction Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 08-08-46-008C > Jan > 11 > OnStar(R) - Generation 8.0L Software Update > Page 9604 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by either the GM Customer Assistance Center or by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Dealer Action If any or all of the above conditions have been met, dealer technicians should reprogram the OnStar(R) VCIM. A revised service calibration has been released to address this condition. Reprogram the OnStar(R) VCIM using the TIS2WEB Service Programming System (SPS) application. Notice After the programming, perform the following steps to clear the old nametags from the system that may not be working. 1. Connect the scan tool to the vehicle and navigate to the VCIM special functions menu. 2. Change the language setting to either French or Spanish and save. Then power off the vehicle. 3. Power up the vehicle and change the language setting back to English and save. Then power off the vehicle. 4. Power up the vehicle and press the phone icon button on the OnStar(R) button assembly. After the "Ready" prompt, reply "delete all nametags." Note Always make sure your Tech 2(R) is updated with the latest software version. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9613 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9614 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9615 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9621 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9622 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9623 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9632 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9633 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9634 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9640 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9641 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9642 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement Removal Procedure 1. Remove the front bumper. Refer to Front Bumper Replacement (See: Body and Frame/Bumper/Front Bumper/Service and Repair). 2. Remove the right tow hook nuts and bolts from the frame rail. 3. Remove the right tow hook from the vehicle. 4. Remove the left tow hook nuts and bolts from the frame rail. 5. Remove the left tow hook from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Page 9652 1. Install the left tow hook to the frame rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nuts and the bolts to the frame rail and tighten the bolts to 100 Nm (74 lb ft). 3. Install the left tow hook to the frame rail. 4. Install the nuts and the bolts to the frame rail and tighten the bolts to 100 Nm (74 lb ft). 5. Install the front bumper. Refer to Front Bumper Replacement (See: Body and Frame/Bumper/Front Bumper/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams Trailer Connector: Diagrams Component Connector End Views Trailer Connector (UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Weight Distributor Hitch Platform Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Service and Repair Trailer Lighting Module: Service and Repair Trailer Lamp Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams Trailer Connector: Diagrams Component Connector End Views Trailer Connector (UY7) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: Customer Interest Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-56-001 > Mar > 09 > Body Controls - Security Lamp ON After Start Up Body Control Module: All Technical Service Bulletins Body Controls - Security Lamp ON After Start Up TECHNICAL Bulletin No.: 09-08-56-001 Date: March 12, 2009 Subject: Security Light Remains Illuminated After Vehicle Has Started/No Stored DTCs (Reprogram BCM) Models: 2009 Chevrolet Colorado 2009 GMC Canyon 2009 HUMMER H3, H3T Note The information contained in this bulletin applies to vehicles located in the U.S. only. Condition Some customers may comment that the Security Light remains illuminated after the vehicle has started. Upon further investigation, no DTCs will be found in the Body Control Module (BCM) and Engine Control Module (ECM). Cause This condition may have occurred when the ignition switch was rotated from "Crank" back to "Run" and momentarily went too far and entered "Accessory" for a fraction of a second. When the BCM sees the Accessory signal after being in "Crank" it is again waiting for the Passlock signal in the "Crank" mode to turn the light off. Correction Important Do Not replace the ignition switch for this concern. 1. Verify the customer concern. 2. If there is a stored DTC (ECM and BCM), follow published diagnostics in SI. 3. If the concern can be verified and there are no DTCs, reprogram the BCM using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. Make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9685 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9686 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9687 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9688 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9689 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9695 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9696 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9697 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9698 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-67-001B > Jun > 09 > Body Water leaks/ Wind Noise From The Sunroof > Page 9699 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views Body Control Module: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 9702 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 9703 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 9704 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 - Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 - Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 - X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 9705 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 9706 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Harness Routing Views > Page 9707 Body Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Right Kick Panel Components 1 - Body Harness 2 - Instrument Panel Harness 3 - Body Control Module (BCM) 4 - X201 5 - Body Control Module (BCM) X2 6 - Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9708 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9709 Body Control Module (BCM) X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9710 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9711 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9712 Body Control Module: Service and Repair Body Control Module Replacement Removal Procedure Important: * The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). * Always disconnect the black body wiring harness connector FIRST and the gray instrument panel (I/P) wiring harness connector LAST. * Always connect the black body wiring harness connector FIRST and the gray I/P wiring harness LAST. * Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Ensure the ignition switch is in the OFF position. 2. Remove the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Disconnect the body wiring harness electrical connector (1) from the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9713 4. Disconnect the I/P wiring harness electrical connector (1) from the BCM. 5. Release the fastener retaining the body wiring harness electrical connector to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9714 6. Remove the 2 fasteners retaining the BCM to the hinge pillar. 7. Remove the BCM from the hinge pillar by unlocking the integral tab. 8. Remove the BCM from the vehicle. Installation Procedure 1. Position the BCM to the vehicle. 2. Attach the BCM to the hinge pillar with the integral tab. 3. Install the 2 fasteners retaining the BCM to the hinge pillar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9715 4. Install the fastener retaining the body wiring harness electrical connector to the BCM. 5. Connect the body wiring harness electrical connector (1) to the BCM. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9716 6. Connect the I/P wiring harness electrical connector (1) to the BCM. 7. Install the right front hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 8. If installing a replacement BCM, program the BCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Replacement Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Replacement Front Bumper Fascia Replacement (Canyon/Colorado) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front bumper (1) assembly. Refer to Front Bumper Replacement (See: Service and Repair). 3. Remove the push-pins retaining the fascia (2) to the front bumper. 4. Pull the fascia straight forward to remove. Installation Procedure 1. Install the fascia (2) to the front bumper. 2. Install the push-pins retaining the fascia to the front bumper. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Replacement > Page 9725 3. Install the front bumper (1) assembly. Refer to Front Bumper Replacement (See: Service and Repair). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Replacement > Page 9726 Front Bumper Cover / Fascia: Service and Repair Front Bumper Lower Fascia Trim Insert Grille Replacement Front Bumper Lower Fascia Trim Insert Grille Replacement (Colorado) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Rear Bumper Impact Bar Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 9736 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Reinforcement Replacement Rear Bumper Impact Bar Reinforcement Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 9737 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Brace Replacement Rear Bumper Impact Bar Brace Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 9738 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Bracket Replacement Rear Bumper Impact Bar Bracket Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 2. Remove the air inlet grill panel push-pin retainers. 3. Disconnect the washer hose. 4. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Position the air inlet grille panel to the vehicle. 2. Connect the washer hose. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 9746 3. Install the push-pin retainers. 4. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 3. Disconnect the outside door handle rod by releasing the retaining clip (2). 4. Disconnect the lock cylinder rod by releasing the retaining clip (1). 5. Remove the bolts retaining the outside door handle to the door. 6. Remove the outside door handle from the door. 7. Remove the lock cylinder from the outside door handle. Refer to Front Side Door Lock Cylinder Replacement (See: Locks/Door Locks/Door Lock Cylinder/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 9754 Installation Procedure 1. Install the lock cylinder to the outside door handle. Refer to Front Side Door Lock Cylinder Replacement (See: Locks/Door Locks/Door Lock Cylinder/Service and Repair). 2. Install the outside door handle to the front door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts retaining the outside door handle to the door. Tighten the outside door handle bolts to 9 Nm (80 lb in). 4. Connect the lock cylinder rod to the lock cylinder using the retaining clip (1). 5. Connect the outside door handle rod to the door handle using the retaining clip (2). 6. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 7. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). 2. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 3. Slide the inside door handle rearward to release the retaining tabs (1) from the door inner panel. 4. Remove the lock cables from the inside door handle. 5. Remove the inside door handle from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Page 9758 1. Install the lock cables to the inside door handle. 2. Insert the inside door handle retaining tabs (1) into the slots of the door inner panel. 3. Slide the inside door handle forward until the door handle retainers are fully engaged. 4. Install the water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 5. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side Front Door Hinge: Service and Repair Front Side Door Hinge Replacement - Body Side Front Side Door Hinge Replacement - Body Side Removal Procedure 1. Open the front door. 2. Remove the bolt retaining the front door check link to the body. 3. Remove the front door wiring harness grommet from the body, and disconnect the door wiring harness connectors. Refer to Front Side Door Wiring Harness Replacement (See: Service and Repair). 4. Remove the bolts (1) retaining the front door hinge keeper straps. 5. With an assistant, lift the front door up off the body side hinges, and place on a clean protected surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9763 6. Clean the mounting surfaces of the body side hinges with a clean rag, and mark the front door hinge locations with a grease pencil, or other suitable marker. 7. Remove the bolts retaining the body side hinges to the body. 8. Remove the hinges from the body. Installation Procedure 1. Position the body side front door hinge to the alignment marks. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the body side door hinge to the body and tighten to 27 Nm (20 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9764 3. With an assistant, lower the front door down onto the body side hinge straps. 4. Install the bolts (1) retaining the front door hinge keeper straps and tighten to 25 Nm (18.4 lb ft). 5. Connect the front door wiring harness connectors, and install the front door wiring harness grommet to the body. Refer to Front Side Door Wiring Harness Replacement (See: Service and Repair). 6. Install the bolt retaining the front door check link to the body and tighten to 25 Nm (18.4 lb ft). 7. Inspect the door for proper operation and alignment. Refer to Front Side Door Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9765 Front Door Hinge: Service and Repair Front Side Door Hinge Replacement - Door Side Front Side Door Hinge Replacement - Door Side Removal Procedure 1. Open the front door. 2. Remove the bolt retaining the front door check link to the body. 3. Remove the front door wiring harness grommet from the body and disconnect the door wiring harness connectors. Refer to Front Side Door Wiring Harness Replacement (See: Service and Repair). 4. Remove the bolts (1) retaining the front door hinge keeper straps. 5. With the aid of an assistant, lift the front door up off the body side hinges and place the door on a clean, protected surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9766 6. Remove the bolts retaining the door side hinges to the door. 7. Remove the hinges from the door. Installation Procedure 1. Position the door side front door hinge to the door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the door side door hinge to the door and tighten to 27 Nm (20 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Side Door Hinge Replacement - Body Side > Page 9767 3. With the aid of an assistant, lower the front door down onto the body side hinge straps. 4. Install the bolts (1) retaining the front door hinge keeper straps and tighten to 25 Nm (18 lb ft). 5. Connect the front door wiring harness connectors and install the front door wiring harness grommet to the body. Refer to Front Side Door Wiring Harness Replacement (See: Service and Repair). 6. Install the bolt retaining the front door check link to the body and tighten to 25 Nm (18 lb ft). 7. Inspect the door for proper operation and alignment. Refer to Front Side Door Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair Front Side Door Check Link Replacement Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 3. Remove the bolt retaining the front door check link to the body. 4. Remove the nuts retaining the front door check link to the door. 5. Remove the front door check link (1) from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair > Page 9771 1. Install the front door check link to the door, ensuring the alignment mark (1) faces upward. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nuts retaining the front door check link to the door and tighten to 9 Nm (80 lb in). 3. Install the bolt retaining the front door check link to the body and tighten to 25 Nm (18.4 lb ft). 4. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 5. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Panel Replacement Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement Front Side Door Trim Panel Replacement Special Tools J 9886-01 Door Handle Clip Remover Removal Procedure 1. Remove the window regulator handle from the door by inserting tool J 9886-01 between the handle and the white plastic washer to remove the retaining clip, if the vehicle is equipped with manual windows. 2. Remove the retaining screw from the door handle bezel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9776 3. Remove the 2 retaining screws from the armrest and lift the front of the switch plate to disengage the clip. 4. Disconnect the electrical harness (3-4) from the power window switch (2, 5), if equipped. 5. Remove the upper trim cover from the door. 6. Gently pull the door panel away from the door. 7. Remove any fasteners from the door and reinsert them in the door panel before installing the panel on the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9777 1. Install the trim panel to the door, ensuring that all the retaining tabs are fully seated. 2. Connect the electrical harness (3-4) to the power window switch (2, 5), if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9778 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 retaining screws in the switch plate. Tighten the front door switch plate screws to 2 Nm (18 lb in). 4. Install the retaining screw in the door handle bezel. Tighten the front door handle bezel screws to 2 Nm (18 lb in). 5. Install the window regulator handle from the door and insert the clip between the handle and the white plastic washer, if the vehicle is equipped with manual windows. 6. Install the upper trim cover to the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9779 Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: ). 2. Remove the front door water deflector from the front door inner panel. 3. Pull the electrical connectors through the slit in the water deflector. Installation Procedure 1. Align the front door water deflector to the front door inner panel. Secure the water deflector at the corners. 2. Pull the front door electrical connectors through the slit in the water deflector. 3. Install the front door water deflector. Start pressing the adhesive pattern at the bottom center and working outward and upward in order to prevent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 9780 puckering. 4. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments Door Lock Striker Adjustment 1. Ensure that the door is properly aligned within the door opening before proceeding with the striker adjustment. Refer to Front Side Door Adjustment (See: Adjustments) and Rear Door Adjustment (See: Rear Door/Adjustments). 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note closing effort to fully engage the latch. 3. Mark the position of the door striker with a grease pencil. 4. Loosen the screws retaining the door striker to the body. 5. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement ensuring that the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the screws retaining the door striker to the body. Tighten the door striker screws to 25 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 9784 Front Door Striker: Service and Repair Door Striker Replacement Removal Procedure 1. Mark the position of the door striker with a grease pencil. 2. Remove the screw retaining the door striker to the body. 3. Remove the door striker from the body. Installation Procedure 1. Install the door striker to the body. 2. Align the lock striker to the alignment marks. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 9785 3. Install the door striker screws to the body. Tighten the door striker screws to 25 Nm (18 lb ft). 4. Adjust the lock striker if required. Refer to Door Lock Striker Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Auxiliary Weatherstrip Replacement Auxiliary Weatherstrip Replacement Crew cab shown, others similar. Removal Procedure 1. Open the front and rear door, as necessary. 2. Remove the auxiliary weatherstrip by pulling the weatherstrip (1) from the roof pinchweld flange (2). Installation Procedure 1. Install the auxiliary weatherstrip to the roof pinchweld flange by pressing the weatherstrip (1) onto the roof flange (2), until it is fully seated. 2. Close the front and rear door, as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9790 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended) Front Door Opening Weatherstrip Replacement (Extended) Removal Procedure 1. Open the front and rear door. 2. Remove the front door opening weatherstrip (1) from the opening pinchweld flange. 3. Remove the front door opening weatherstrip from the vehicle. Installation Procedure 1. Align the paint dot on the front door weatherstrip to the notch (2) in the upper rear corner of the pitchweld flange. 2. Starting at the notch (2) in the upper rear corner, press the front door opening weatherstrip (1) onto the pinchweld flange until it is fully seated. 3. Pull the cord (3) on the front door opening weatherstrip, ensuring the weatherstrip lip overlaps the interior trim panels and headliner. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9791 4. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9792 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular, Crew) Front Door Opening Weatherstrip Replacement (Regular, Crew) Removal Procedure 1. Open the front door. 2. Remove the lower center pillar panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the front door opening weatherstrip (2) from the door opening pinchweld flange (1). 4. Remove the front door opening weatherstrip from the vehicle. Installation Procedure 1. Position the front door opening weatherstrip to the pinchweld flange. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9793 2. Starting at the upper rear corner, press the front door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Pull the cord (3) on the front door opening weatherstrip ensuring the weatherstrip lip overlaps the interior trim panels and headliner. 5. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9794 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement (Extended) Front Side Door Weatherstrip Replacement (Extended) Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the front door. 2. Remove the upper weatherstrip mold from the door by removing the integral weatherstrip pushpin (2) from the door using J 38778 , or equivalent. 3. Remove the lower weatherstrip mold from the door removing the integral weatherstrip pushpin (3) from the door using J 38778 , or equivalent. 4. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent, under the weatherstrip (1), and releasing the integral retainers from the door frame. 5. Remove the weatherstrip from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9795 1. Position the weatherstrip to the front door. 2. Install the upper weatherstrip mold to the door using the integral weatherstrip pushpin (2). 3. Install the lower weatherstrip mold to the door using the integral weatherstrip pushpin (3). 4. Install the weatherstrip around the front door frame using the integral retainers. 5. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9796 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement (Regular, Crew) Front Side Door Weatherstrip Replacement (Regular, Crew) Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the front door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent , under the weatherstrip (1) and releasing the integral retainers from the door frame. 3. Remove the weatherstrip from the front door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 9797 1. Position the weatherstrip to the front door. 2. Install the weatherstrip around the front door frame using the integral retainers. 3. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Glass: Customer Interest Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9806 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9807 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 9817 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Glass: All Technical Service Bulletins Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9822 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9823 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start Fuse: All Technical Service Bulletins Electrical - Dead Battery/No Crank/No Start TECHNICAL Bulletin No.: 08-06-03-010 Date: September 30, 2008 Subject: Battery Runs Down, Engine Will Not Crank, No Start, Instrument Panel Cluster (IPC) Charge Indicator Turns On, Driver Information Center (DIC) Displays Service Charge System Message (Install 125 Amp Mega Fuse) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon 2007-2009 HUMMER H3 Condition Some customers may comment on the following conditions: ^ The battery runs down. ^ The engine will not crank. ^ The engine will not start. ^ The Instrument Panel Cluster charge indicator turns on. ^ The Driver Information Center displays a Service Charge System message. Cause This condition may be caused by an open Mega Fuse in the underhood electrical center. Correction Technicians are to diagnose the charging system concern using the diagnostics in SI. Install a new Mega Fuse if it is found to be open. On 2007 and 2008 model year vehicles, if the vehicle currently has a 100 Amp Mega Fuse replace it with a 125 Amp Mega Fuse. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 08-06-03-010 > Sep > 08 > Electrical - Dead Battery/No Crank/No Start > Page 9829 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9830 Front Door Window Glass: By Symptom Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9831 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9832 Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9833 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9834 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9835 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9836 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9837 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 9838 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 9839 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Removal Procedure 1. Position the front door window approximately halfway down. 2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). 3. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 4. Remove the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (See: Windows and Glass/Windows/Service and Repair/Front Side Door Window Belt Outer Sealing Strip Replacement). 5. Remove the bolts retaining the front door window to the window regulator. 6. Lift the window off of the window regulator. 7. Rotate the rear of the window upwards, disengaging the window from the window run channel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 9840 8. Remove the window from between the inner and outer door panels. Installation Procedure 1. Install the front door window into the front door between the inner and outer door panels. 2. Rotate the rear of the window down, positioning the window into the window run channels. 3. Lower the window down onto the window regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolts retaining the front door window to the window regulator. Tighten the front window bolts to 9 Nm (80 lb in). 5. Install the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (See: Windows and Glass/Windows/Service and Repair/Front Side Door Window Belt Outer Sealing Strip Replacement). 6. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 7. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Removal Procedure Warning Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 1. Remove the front door window regulator. Refer to Front Side Door Window Regulator Replacement (See: Front Door Window Regulator/Service and Repair/Front Side Door Window Regulator Replacement). 2. Drill a hole (1) through the window regulator bracket and lift arm. 3. Install a nut and bolt through the hole (1) to secure the lift arm while the motor is removed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 9844 4. Remove the bolts retaining the front window regulator motor to the regulator bracket. 5. Remove the front window regulator motor from the regulator. Installation Procedure 1. Install the front window regulator motor to the regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the front window regulator motor to the regulator bracket. Tighten the front window regulator motor bolts to 4.5 Nm (40 lb in). 3. Remove the nut and bolt securing the lift arm to the regulator bracket. 4. Install the front window regulator to the front door. Refer to Rear Side Door Window Regulator Replacement (See: Rear Door/Rear Door Window Regulator/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Regulator: Customer Interest Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9853 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9854 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9860 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 9861 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9862 Front Door Window Regulator: By Symptom Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9863 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9864 Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9865 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9866 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9867 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9868 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9869 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 9870 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Handle Replacement Door Window Regulator Handle Replacement Tools Required J 9886-01 Door Handle Clip Remover Removal Procedure 1. Raise the window to the full up position. 2. Remove the window regulator handle from the door by inserting tool J 9886-01 between the handle and the white plastic washer. 3. Align the J 9886-01 with the handle. 4. Push the J 9886-01 in order to disengage the clip. 5. Pull the handle from the door. 6. Remove the window regulator handle from the door. 7. Remove the bearing plate from the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9873 Installation Procedure 1. Ensure that the window is in the full up position. 2. Install the white plastic washer to the regulator shaft. 3. Install the retaining clip to the handle. 4. Install the window regulator handle to the door with the handle forward at about a 50 degree angle. 5. Push on the handle until the clip engages on the shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9874 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement Front Side Door Window Regulator Replacement Power window regulator (A31) shown, manual window regulator (without A31) similar. Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 3. Remove the bolts retaining the front door window to the window regulator. 4. Remove the front door window. Refer to Front Side Door Window Replacement (See: Front Door Window Glass/Service and Repair). 5. Disconnect the electrical connector from the window regulator motor, if equipped with A31. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9875 6. Loosen the bolts (1) retaining the window regulator to the inner panel at the keyhole slot locations. 7. Remove the remaining fasteners retaining the window regulator to the inner panel. 8. Remove the window regulator from the door by lifting the regulator up, and out of the keyhole slots, and removing the regulator out through the access hole. Installation Procedure 1. Install the front door window regulator into the front door through the access hole. 2. Position the window regulator to the inner panel by sliding the regulator bolts (1) into the keyhole slots in the inner panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fastener retaining the front door window regulator to the door. Tighten the front window regulator fasteners to 9 Nm (80 lb in). 4. Connect the electrical connector to the window regulator motor, if equipped with A31. 5. Install the front door window. Refer to Front Side Door Window Replacement (See: Front Door Window Glass/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 9876 6. Install the bolts retaining the window to the window regulator. Tighten the front door window bolts to 9 Nm (80 lb in). 7. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair). 8. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 2. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 3. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Interior Handle/Service and Repair). 4. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 5. Disconnect the rear outside door handle rod by releasing the retaining clip (1). 6. Remove the bolts retaining the rear outside door handle to the door. 7. Remove the rear outside door handle from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 9882 1. Install the rear outside door handle to the rear door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the rear outside door handle to the door. Tighten the outside door handle bolts to 9 Nm (80 lb in). 3. Connect the rear outside door handle rod to the door handle using the retaining clip (1). 4. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 5. Install the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Interior Handle/Service and Repair). 6. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 7. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle Replacement Rear Door Interior Handle: Service and Repair Rear Side Access Door Inside Handle Replacement Rear Side Access Door Inside Handle Replacement Tools Required J 9886-01 Door Handle Clip Remover or equivalent Removal Procedure 1. Open the front and rear side access door. 2. Remove the spring clip retaining the rear side access door handle by inserting J 9886-01 between the door handle, and the door, and pressing the spring clip off the door handle. 3. Remove the rear side access door handle from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle Replacement > Page 9887 1. Install the spring clip onto the rear side access door handle. 2. Install the rear side access door handle onto the rear side access door control assembly. 3. Press the handle in until the spring clip retaining the handle is fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle Replacement > Page 9888 Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement Rear Side Door Inside Handle Replacement Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 2. Slide the inside door handle rearward to release the retaining tabs (1) from the door inner panel. 3. Remove the lock cables from the inside door handle. 4. Remove the inside door handle from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Access Door Inside Handle Replacement > Page 9889 1. Install the lock cables inside the door handle. 2. Insert the inside door handle retaining tabs (1) into the slots of the door inner panel. 3. Slide the inside door handle forward until the door handle retainers are fully engaged. 4. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement Rear Door Hinge: Service and Repair Rear Side Access Door Hinge Replacement Rear Side Access Door Hinge Replacement Removal Procedure Note: In order to minimize door realignment, do not remove both the door hinges at the same time. Replace the broken hinge first. 1. Open the front and rear side access door. 2. Clean the mounting surfaces of the hinges with a clean rag, and mark the rear door hinge locations on each surface with a grease pencil, or other suitable marker. 3. Support the rear side access door. 4. Remove the bolts retaining the hinge to the door. 5. Remove the bolts retaining the hinge to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9894 6. Remove the rear side access door hinge from the body. Installation Procedure 1. Position the rear side access door hinge to the alignment marks. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the hinge to the body and tighten to 25 Nm (18.4 lb ft). 3. Install the bolts retaining the hinge to the door and tighten to 25 Nm (18.4 lb ft). 4. Remove the support from the rear side access door. 5. Inspect the door for proper operation and alignment. Refer to Rear Door Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9895 Rear Door Hinge: Service and Repair Rear Side Door Hinge Replacement - Body Side Rear Side Door Hinge Replacement - Body Side Removal Procedure 1. Open the door. 2. Remove the bolt retaining the rear door check link to the body. 3. Remove the rear door wiring harness grommet from the body, and disconnect the door wiring harness connectors. Refer to Rear Side Door Wiring Harness Replacement (See: Service and Repair). 4. Remove the bolts (1) retaining the rear door hinge keeper straps. 5. With an assistant, lift the rear door up off the body side hinges, and place on a clean protected surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9896 6. Clean the mounting surfaces of the body side hinges with a clean rag and mark the rear door hinge locations with a grease pencil or other suitable marker. 7. Remove the bolts retaining the body side hinges to the body. 8. Remove the hinges from the body. Installation Procedure 1. Position the body side rear door hinge to the alignment marks. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the body side door hinge to the body and tighten to 25 Nm (18.4 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9897 3. With an assistant, lower the rear door down onto the body side hinge straps. 4. Install the bolts (1) retaining the rear door hinge keeper straps and tighten to 25 Nm (18.4 lb ft). 5. Connect the rear door wiring harness connectors, and install the rear door wiring harness grommet to the body. Refer to Rear Side Door Wiring Harness Replacement (See: Service and Repair). 6. Install the bolt retaining the rear door check link to the body and tighten to 25 Nm (18.4 lb ft). 7. Inspect the door for proper operation and alignment. Refer to Rear Door Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9898 Rear Door Hinge: Service and Repair Rear Side Door Hinge Replacement - Door Side Rear Side Door Hinge Replacement - Door Side Removal Procedure 1. Open the rear door. 2. Remove the bolt retaining the rear door check link to the body. 3. Remove the rear door wiring harness grommet from the body and disconnect the door wiring harness connectors. Refer to Rear Side Door Wiring Harness Replacement (See: Service and Repair). 4. Remove the bolts (1) retaining the rear door hinge keeper straps. 5. With the aid of an assistant, lift the rear door up off the body side hinges and place the door on a clean, protected surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9899 6. Remove the bolts retaining the door side hinges to the door. 7. Remove the hinges from the door. Installation Procedure 1. Position the door side rear door hinge to the door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the door side door hinge to the door and tighten to 25 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Access Door Hinge Replacement > Page 9900 3. With the aid of an assistant, lower the rear door down onto the body side hinge straps. 4. Install the bolts (1) retaining the rear door hinge keeper straps and tighten to 25 Nm (18 lb ft). 5. Connect the rear door wiring harness connectors and install the rear door wiring harness grommet to the body. Refer to Rear Side Door Wiring Harness Replacement (See: Service and Repair). 6. Install the bolt retaining the rear door check link to the body and tighten to 25 Nm (18 lb ft). 7. Inspect the door for proper operation and alignment. Refer to Rear Door Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door Rear Door Latch: Service and Repair Latch Control Assembly Replacement Rear Side Access Door Latch Control Assembly Replacement Rear Side Access Door Removal Procedure 1. Open the rear side access door. 2. Remove the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 3. Remove the rear side access door latch control handle. Refer to Rear Side Access Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 4. Disconnect the upper latch rod (1) from the control assembly by releasing the retaining clip (2). 5. Disconnect the lower latch rod from the control assembly by releasing the retaining clip (3). 6. Remove the bolts retaining the latch control assembly from the rear side access door. 7. Remove the latch control assembly from the rear side access door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9905 1. Install the latch control assembly to the rear side access door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the latch control assembly to the rear side access door. Tighten the latch control assembly bolts to 9 Nm (80 lb in). 3. Connect the lower latch rod to the latch control assembly using the retaining clip (3). 4. Connect the upper latch rod (1) to the control assembly using the retaining clip (2). 5. Install the rear side access door latch control handle. Refer to Rear Side Access Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 6. Install the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 7. Close the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9906 Rear Door Latch: Service and Repair Rear Side Access Door Latch Replacement - Lower Rear Side Access Door Latch Replacement - Lower Removal Procedure 1. Open the rear side access door. 2. Remove the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 3. Disconnect the lower latch rod (1) from the latch by releasing the retaining clip (2). 4. Remove the bolts retaining the lower latch to the rear side access door. 5. Remove the nut retaining the lower latch to the rear side access door. 6. Remove the lower latch from the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9907 Installation Procedure 1. Install the lower latch to the rear side access door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the lower latch to the rear side access door. Tighten the rear side access door lower latch bolts to 9 Nm (80 lb in). 3. Install the nut retaining the lower latch to the rear side access door. Tighten the rear side access door lower latch nut to 9 Nm (80 lb in). 4. Connect the lower latch rod (1) to the latch using the retaining clip (2). 5. Install the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9908 6. Close the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9909 Rear Door Latch: Service and Repair Rear Side Access Door Latch Replacement - Upper Rear Side Access Door Latch Replacement - Upper Removal Procedure 1. Open the rear side access door. 2. Remove the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 3. Disconnect the upper latch rod from the latch by releasing the retaining clip. 4. Remove the bolts (1, 2) retaining the upper latch to the rear side access door. 5. Remove the upper latch from the rear side access door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Control Assembly Replacement Rear Side Access Door > Page 9910 1. Install the upper latch to the rear side access door. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Loosely install the lower bolts (2) retaining the upper latch to the rear side access door. Tighten the lower rear side access door upper latch bolts (2) until the latch bracket is flush to the door panel. 3. Connect the upper latch rod to the latch using the retaining clips. 4. Close the rear side access door to self align the upper latch. 5. Finish tightening the lower rear side access door upper latch bolts. Tighten the upper latch bolts to 9 Nm (80 lb in). 6. Open the rear side access door. 7. Install the upper rear side access door upper latch bolt (1). Tighten the upper latch bolt to 9 Nm (80 lb in). 8. Install the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 9. Close the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Door Check Link Replacement Rear Side Access Rear Door Limiter: Service and Repair Door Check Link Replacement Rear Side Access Door Check Link Replacement Rear Side Access Removal Procedure 1. Remove the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 2. Remove the bolt retaining the rear side access door check link to the body. 3. Remove the nuts retaining the rear side access door check link to the door. 4. Remove the rear side access door check link (1) from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Door Check Link Replacement Rear Side Access > Page 9915 1. Install the rear side door check link to the door, ensuring the alignment mark (1) faces upward. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nuts retaining the rear side door check link to the door and tighten to 9 Nm (80 lb in). 3. Install the bolt retaining the rear side access check link to the body and tighten to 25 Nm (18.4 lb ft). 4. Install the rear side access door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Door Check Link Replacement Rear Side Access > Page 9916 Rear Door Limiter: Service and Repair Rear Side Door Check Link Replacement Rear Side Door Check Link Replacement Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 2. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 3. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 4. Remove the bolt retaining the rear door check link to the body. 5. Remove the nuts retaining the rear door check link to the door. 6. Remove the rear door check link from the door (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Door Check Link Replacement Rear Side Access > Page 9917 Installation Procedure 1. Install the rear door check link to the door, ensuring the alignment mark (1) faces upward. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nuts retaining the rear door check link to the door and tighten to 9 Nm (80 lb in). 3. Install the bolt retaining the check link to the body and tighten to 25 Nm (18.4 lb ft). 4. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 5. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 6. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement Rear Door Panel: Service and Repair Rear Side Access Door Trim Panel Replacement Rear Side Access Door Trim Panel Replacement Removal Procedure 1. Remove the front seat belt assembly. Refer to Front Seat Belt Replacement (Crew Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt Replacement (Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Regular and Extended Cab)). 2. Remove the 2 retaining screws from the armrest. 3. Gently pull the lower side access door trim panel away from the door. 4. Remove any fasteners from the door and reinsert them in the lower side access door trim panel before installing the panel on the door. 5. Grasp the upper side access door trim panel and pull panel away from the door to release the fasteners. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9922 6. Remove any fasteners from the door and reinsert them in the upper side access door trim panel before installing the panel on the door. Installation Procedure 1. Install the upper side access door trim panel to the door, ensuring that all the retaining tabs are fully seated. 2. Install the lower side access door trim panel to the door, ensuring that all the retaining tabs are fully seated. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 retaining screws in the armrest. Tighten the rear side access door armrest screws to 2 Nm (18 lb in). 4. Install the front seat belt assembly. Refer to Front Seat Belt Replacement (Crew Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt Replacement (Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Regular and Extended Cab)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9923 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement Rear Side Door Trim Panel Replacement Special Tools J 9886-01 Door Handle Clip Remover Removal Procedure 1. Remove the window regulator handle from the door by inserting tool J 9886-01 between the handle and the white plastic washer to remove the retaining clip, if the vehicle is equipped with manual windows. 2. Remove the retaining screw from the door handle bezel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9924 3. Remove the 2 retaining screws from the armrest. 4. Disconnect the electrical harness from the power window switch, if equipped. 5. Gently pull the door panel away from the door. 6. Remove any fasteners from the door and reinsert them in the door panel before installing the panel on the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9925 1. Install the trim panel to the door, ensuring that all the retaining tabs are fully seated. 2. Connect the electrical harness to the power window switch, if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9926 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 retaining screws in the switch plate. Tighten the rear door switch plate screws to 2 Nm (18 lb in). 4. Install the retaining screw in the door handle bezel. Tighten the rear door handle bezel screws to 2 Nm (18 lb in). 5. Install the window regulator handle from the door and insert the clip between the handle and the white plastic washer, if the vehicle is equipped with manual windows. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9927 Rear Door Panel: Service and Repair Rear Side Door Water Deflector Replacement Rear Side Door Water Deflector Replacement Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: ). 2. Remove the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 3. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 4. Remove the rear door water deflector from the rear door inner panel. 5. Pull the electrical connectors through the slit in the water deflector. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Access Door Trim Panel Replacement > Page 9928 1. Align the rear door water deflector to the rear door inner panel. Secure the water deflector at the corners. 2. Pull the rear door electrical connectors through the slit in the water deflector. 3. Install the rear door water deflector. Start pressing the adhesive pattern at the bottom center and working outward and upward in order to prevent puckering. 4. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 5. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 6. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments Door Lock Striker Adjustment 1. Ensure that the door is properly aligned within the door opening before proceeding with the striker adjustment. Refer to Front Side Door Adjustment (See: Front Door/Adjustments) and Rear Door Adjustment (See: Adjustments). 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note closing effort to fully engage the latch. 3. Mark the position of the door striker with a grease pencil. 4. Loosen the screws retaining the door striker to the body. 5. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement ensuring that the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the screws retaining the door striker to the body. Tighten the door striker screws to 25 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower Rear Door Striker: Service and Repair Rear Side Door Latch Striker Replacement - Lower Rear Side Door Latch Striker Replacement - Lower Removal Procedure 1. Open the rear side access door. 2. Remove the bolts retaining the lower side access door striker to the body. 3. Remove the lower side access door striker from the body. Installation Procedure 1. Install the lower side access door striker to the body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower > Page 9934 2. Install the bolts retaining the lower side access door striker to the body. Tighten the lower side access door striker bolts to 25 Nm (18 lb ft). 3. Close the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower > Page 9935 Rear Door Striker: Service and Repair Rear Side Door Latch Striker Replacement - Upper Rear Side Door Latch Striker Replacement - Upper Removal Procedure 1. Open the rear side access door. 2. Remove the rear side access upper door striker trim cover. Refer to Rear Side Door Latch Striker Cover Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the bolts retaining the upper side access door striker to the body. 4. Remove the upper side access door striker from the body. Installation Procedure 1. Install the upper side access door striker to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Rear Side Door Latch Striker Replacement - Lower > Page 9936 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the upper side access door striker to the body. Tighten the upper side access door striker bolts to 25 Nm (18 lb ft). 3. Install the rear side access upper door striker trim cover. Refer to Rear Side Door Latch Striker Cover Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Close the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Removal Procedure 1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4. Remove the rear door opening weatherstrip from the vehicle. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9941 2. Starting at the upper rear corner, press the rear door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the interior trim panels and headliner. 5. Close the rear door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9942 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Rear Door Weatherstrip Replacement Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent, under the weatherstrip and releasing the integral retainers (2) from the door frame. 3. Remove the weatherstrip from the rear door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9943 1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame using the integral retainers (2). 3. Close the rear door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9944 Rear Door Weatherstrip: Service and Repair Rear Side Access Door Auxiliary Weatherstrip Replacement Rear Side Access Door Auxiliary Weatherstrip Replacement Removal Procedure 1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by pulling the weatherstrip from the rear door pinchweld flange. Installation Procedure 1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the weatherstrip into place until it is fully seated. 2. Close the front and side doors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9945 Rear Door Weatherstrip: Service and Repair Rear Side Door Wedge Replacement - Body Side Rear Side Door Wedge Replacement - Body Side Removal Procedure 1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint. 3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic, flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and painters (VMP) naptha. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9946 1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C (70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6. Remove the tape from the area around the wedge. 7. Close the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9947 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Removal Procedure 1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4. Remove the rear door opening weatherstrip from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9948 1. Position the rear door opening weatherstrip to the pinchweld flange. 2. Starting at the upper rear corner, press the rear door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the interior trim panels and headliner. 5. Close the rear door. Rear Door Weatherstrip Replacement Rear Door Weatherstrip Replacement Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent, under the weatherstrip and releasing the integral retainers (2) from the door frame. 3. Remove the weatherstrip from the rear door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9949 1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame using the integral retainers (2). 3. Close the rear door. Rear Side Access Door Auxiliary Weatherstrip Replacement Rear Side Access Door Auxiliary Weatherstrip Replacement Removal Procedure 1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by pulling the weatherstrip from the rear door pinchweld flange. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9950 1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the weatherstrip into place until it is fully seated. 2. Close the front and side doors. Rear Side Door Wedge Replacement - Body Side Rear Side Door Wedge Replacement - Body Side Removal Procedure 1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint. 3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic, flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and painters (VMP) naptha. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9951 Installation Procedure 1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C (70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6. Remove the tape from the area around the wedge. 7. Close the rear side access door. Rear Side Door Wedge Replacement - Door Side Rear Side Door Wedge Replacement - Door Side Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9952 1. Open the rear side access door. 2. Remove the wedge from the side access door by squeezing the retainer clip on the wedge and rotating the wedge downward. Installation Procedure 1. Install the wedge to the side access door by inserting the tabs into the slots on the door and rotating the wedge up until the retaining clip is fully seated. 2. Close the rear side access door. Weatherstrip Replacement Rear Side Access Door Weatherstrip Replacement Rear Side Access Door Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9953 Removal Procedure 1. Open the front and rear side access doors. 2. Remove the upper molded detail from the front of the side access door, by inserting J 38778 under the weatherstrip mold and releasing the integral retaining pins (3) on the mold to the door. 3. Remove the lower molded detail from the front of the side access door, by inserting J 38778 under the weatherstrip mold and releasing the integral retaining pins (1) on the mold to the door. 4. Remove the weatherstrip from around the door, by inserting J 38778 under the weatherstrip on releasing the integral pins from the door. 5. Remove the weatherstrip from the side access door. Installation Procedure 1. Position the weatherstrip to the rear side access door. 2. Install the upper molded detail to the front of the rear side access door using the integral retaining pins (1). 3. Install the lower molded detail to the front of the rear side access door using the integral retaining pins (1). 4. Install the weatherstrip around the rear door frame using the integral retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 9954 5. Close the front and rear side access doors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement Removal Procedure 1. Position the rear door window in the full up position. 2. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 3. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 4. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 5. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 6. Remove the rear window run channel. Refer to Rear Side Door Window Channel Replacement (See: Windows and Glass/Windows/Service and Repair/Rear Side Door Window Channel Replacement). 7. Lower the rear door window in the full down position. 8. Remove the bolts retaining the rear door window to the window regulator. 9. Lift the rear window off the regulator. Carefully lower the window down into the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 9958 10. Remove the window from the door by sliding the window out between the inner panel (1) and the upper window channel (2). Installation Procedure 1. Install the rear door window to the rear door by inserting the front edge of the window into the window channel (3), and sliding the rear of the window down between the upper window channel (2) and the inner panel (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 9959 2. Position the rear door window onto the window regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts retaining the rear door window to the window regulator. Tighten the rear window bolts to 9 Nm (80 lb in). 4. Raise the window to the full up position. 5. Install the rear door window run channel. Refer to Rear Side Door Window Channel Replacement (See: Windows and Glass/Windows/Service and Repair/Rear Side Door Window Channel Replacement). 6. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 7. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 8. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 9. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Removal Procedure 1. Remove the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement (See: Rear Door Window Regulator/Service and Repair). 2. Remove the bolts retaining the rear window regulator motor to the regulator bracket. 3. Remove the rear window regulator motor from the regulator. Installation Procedure 1. Install the rear window regulator motor to the regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Page 9963 2. Install the bolts retaining the rear window regulator motor to the regulator bracket. Tighten the rear window regulator motor bolts to 4.5 Nm (40 lb in). 3. Install the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement (See: Rear Door Window Regulator/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement Manual window regulator (without A31) shown, power regulator (A31) similar. Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). 2. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 3. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 4. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 5. Remove the bolts retaining the rear window to the window regulator. 6. Raise and support the rear door window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9967 7. Disconnect the electrical connector from the window regulator motor, if equipped with A31. 8. Loosen the bolts retaining the window regulator (1) to the inner door at the keyhole slot (2) locations. 9. Remove the bolts retaining the window regulator to the inner panel. 10. Remove the window regulator (1) by lifting the regulator up, and out of the keyhole slots (2) in the inner panel, and removing the regulator out through the access hole. Installation Procedure 1. Install the rear door window regulator (1) into the rear door through the access hole. 2. Position the rear door window regulator to the inner panel by inserting the regulator bolts to the keyhole slots (2) on the inner panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts retaining the rear door window regulator to the inner panel. Tighten the rear window regulator bolts to 9 Nm (80 lb in). 4. Connect the electrical connector to the window regulator motor, if equipped with A31. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9968 5. Remove the window support and lower the window onto the window regulator carrier plate. 6. Install the bolts retaining the window to the window regulator. Tighten the rear window bolts to 9 Nm (80 lb in). 7. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair). 8. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 9. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See: Rear Door Handle/Rear Door Interior Handle/Service and Repair). 10. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement Removal Procedure 1. Remove the screws (2) that retain the fuel filler door to the body. 2. Remove the fuel filler door (1) from the body. Installation Procedure 1. Position the fuel filler door (1) to the body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel filler door retaining screws (2) to the body and tighten to 5 Nm (44 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure 1. Remove the hood. Refer to Hood Replacement (See: Service and Repair). 2. Remove the front fender. Refer to Front Fender Replacement (See: Fender/Front Fender/Service and Repair). 3. Using a grease pencil or other suitable marking device, mark the location of the hinges to the body. 4. Remove the bolts that retain the hinges. 5. Remove the hinges from the body. Installation Procedure 1. Position the hinges to the body as previously marked. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 9976 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts that retain the hinges to the body and tighten to 25 Nm (18 lb ft). 3. Install the front fender. Refer to Front Fender Replacement (See: Fender/Front Fender/Service and Repair). 4. Install the hood. Refer to Hood Replacement (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Adjustments Hood Latch: Adjustments Hood Latch Adjustment Inspection Procedure 1. Release the primary hood latch in order to inspect the operation of the pop-up spring. 2. Attempt to raise the hood while the hood is in the pop-up position. * The hood should raise without the hood striker binding against the latch. * The secondary latch should engage in order to prevent the hood from being raised. Adjustment Procedure 1. Loosen the bolts (1, 2) retaining the hood latch to the radiator support and the support bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Move the hood latch from side to side until the striker enters the center of the latch assembly. Tighten the bolts (1, 2) to 10 Nm (89 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Adjustments > Page 9980 Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair). 2. Using a grease pencil or other suitable marking device, mark the location of the latch on the radiator support. 3. Remove the hood latch support (3). 4. Remove the bolts that retain the latch to the radiator support (1). 5. Disconnect the hood latch cable from the latch. 6. Remove the latch from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Adjustments > Page 9981 1. Connect the hood latch cable to the latch. 2. Position the latch to the previously marked location on the radiator support. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts which retain the latch to the radiator support and tighten to 10 Nm (89 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Adjustments > Page 9982 4. Install the hood latch support (3). 5. Install the bolts which retain the latch support and tighten to 10 Nm (89 lb in). 6. Inspect the latch for proper operation before closing the hood. 7. Inspect the alignment of the latch to the hood striker. Adjust the latch, if necessary. Refer to Hood Latch Adjustment (See: Adjustments). 8. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair). 2. Remove the hood latch. Refer to Hood Primary and Secondary Latch Replacement (See: Hood Latch/Service and Repair). 3. Release the hood latch release cable from the hood latch assembly. 4. Attach a length of mechanic's wire to the exterior end of the cable, and note the routing of the cable for later installation. 5. Release the retainers securing the cable to the inner fender and the radiator support. 6. Push the cable grommet (1) through the cowl panel and into the interior of the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 9986 7. Remove the bolts attaching the hood release handle to the knee bolster. 8. Remove the cable from the release handle. 9. Pull the cable the rest of the way through the cowl panel and out from behind the sound insulation. 10. Detach the mechanic's wire from the cable, leaving the wire in position for aid in installation of the cable. 11. Remove the cable from the vehicle. Installation Procedure 1. Attach the mechanic's wire to the exterior end of the cable. 2. Using the mechanic's wire as an aid, guide the cable underneath the sound insulation and pass the exterior portion of the cable through the cowl panel. 3. Install the cable to the release handle. 4. Seat the cable grommet (1) to the cowl panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 9987 5. Install the release handle to the knee bolster. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the bolts that retain the release handle to the knee bolster and tighten to 1 Nm (9 lb in). 7. Route the cable as previously noted. 8. Attach the cable to the retainers on the inner fender. 9. Install the cable to the hood latch assembly. 10. Install the hood latch. Refer to Hood Primary and Secondary Latch Replacement (See: Hood Latch/Service and Repair). 11. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Hood Hold-Open Rod Replacement Removal Procedure 1. Raise the hood. Support the hood with something other than the prop rod. 2. Remove the bolt retaining the prop rod to the radiator support. 3. Remove the prop rod. Installation Procedure 1. Install the prop rod to the radiator support. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Page 9991 2. Install the prop rod bolt and tighten to 10 Nm (89 lb in). 3. Remove the temporary hood support. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Removal Procedure 1. Open the hood. 2. Remove the front hood seal by pulling downward on the seal, starting from one end. Installation Procedure 1. Open the hood. 2. Install the front hood seal by pressing the retainers into the hood openings. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 9996 3. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 9997 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Removal Procedure 1. Open the hood. 2. Grasp the rear hood seal at each retainer and lift upwards to remove. 3. Remove the seal from the upper cowl panel. Installation Procedure 1. Position the seal to the upper cowl panel. 2. Insert each retainer into the holes in the body. 3. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement Endgate Emblem/Nameplate Replacement (GMC Canyon SL) Endgate Emblem/Nameplate Replacement (Colorado LT) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10005 Endgate Emblem/Nameplate Replacement (Colorado LS) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10006 Endgate Emblem/Nameplate Replacement (Colorado) Endgate Emblem/Nameplate Replacement (GMC SLE) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10007 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10008 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (ISUZU i-290) Endgate Emblem/Nameplate Replacement (ISUZU i-290) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10009 Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (ISUZU i-290) Front Side Door Emblem/Nameplate Replacement (ISUZU i-290) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10010 Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (GME) Front Side Door Emblem/Nameplate Replacement (GME) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10011 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement Endgate Emblem/Nameplate Replacement (GMC Canyon SL) Endgate Emblem/Nameplate Replacement (Colorado LT) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10012 Endgate Emblem/Nameplate Replacement (Colorado LS) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10013 Endgate Emblem/Nameplate Replacement (Colorado) Endgate Emblem/Nameplate Replacement (GMC SLE) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10014 Endgate Emblem/Nameplate Replacement (ISUZU i-290) Endgate Emblem/Nameplate Replacement (ISUZU i-290) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10015 Front Side Door Emblem/Nameplate Replacement (ISUZU i-290) Front Side Door Emblem/Nameplate Replacement (ISUZU i-290) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10016 Front Side Door Emblem/Nameplate Replacement (GME) Front Side Door Emblem/Nameplate Replacement (GME) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10017 Front Side Door Emblem/Nameplate Replacement Front Side Door Emblem/Nameplate Replacement (Colorado) Special Tools J 25070 Heat Gun Removal Procedure Note: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the door emblem. 2. Heat the emblem/nameplate, using a J 25070 , 152 mm (6 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Caution: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10018 5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the door surface using varnish makers and painters (VMP) naphtha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked, apply tape and use the following dimensions: * Dimension (a) is 166 mm (6.54 in) from the bottom of the door to the emblem/nameplate. * Dimension (b) is 117.4 mm (4.62 in) from the front of the door to the front of the emblem/nameplate. 2. Warm the door surface with a J 25070 , 152 mm (6 in) from the surface to a minimum of 21°C (70°F). Note: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the door emblem. Pickup Box Side Emblem and Side Rear Nameplate Replacement Pickup Box Side Emblem and Side Rear Nameplate Replacement (Colorado) Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10019 J 25070 Heat Gun Removal Procedure Note: Use the tape for protection and alignment marks for alignment of the new decal. 1. Apply tape to the area around the decal. 2. Heat the decal, using a J 25070 , 152 mm (6 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Caution: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 4. Remove the decal from the painted surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the painted surface using 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the painted surface using varnish makers and painters (VMP) naptha. 7. Remove the tail lamp. Refer to Tail Lamp Replacement (See: Lighting and Horns/Tail Lamp/Service and Repair). Installation Procedure 1. If the location of the decal has not been marked, apply tape and use the following dimensions: * Dimension (a) is 207.1 mm (8.15 in) from the top edge of the pickup box to the highest point on the decal. * Dimension (b) is 71.8 mm (2.83 in) from the rear of the decal to the rear of the sheet metal in the tail lamp opening. 2. Warm the door surface with a J 25070 , 152 mm (6 in) from the surface to a minimum of 21°C (70°F). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement > Page 10020 Note: Do not touch the adhesive backing on the decal. 3. Remove the backing from the front end of the decal. 4. Press the decal to the painted surface while continuing to remove the backing. 5. Hand roll the decal to the panel to ensure proper adhesion. 6. Inspect the decal for bonding. 7. Remove the tape from the area around the decal. 8. Install the tail lamp. Refer to Tail Lamp Replacement (See: Lighting and Horns/Tail Lamp/Service and Repair). Radiator Grille Emblem/Nameplate Replacement Radiator Grille Emblem/Nameplate Replacement Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair). 2. Place the grille on a clean, prepared surface. 3. Remove the emblem retaining nuts. 4. Remove the emblem from the grille. Installation Procedure 1. Install the emblem to the grille. Notice: Refer to Fastener Notice . 2. Install the nuts that retain the emblem to the grille. Tighten the nuts to 3 Nm (27 lb in). 3. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 2. Remove the air inlet grill panel push-pin retainers. 3. Disconnect the washer hose. 4. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Position the air inlet grille panel to the vehicle. 2. Connect the washer hose. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 10024 3. Install the push-pin retainers. 4. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair Lower Side Moulding / Trim: Service and Repair Body Side Lower Rear Molding Replacement (B84) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair Upper Side Moulding / Trim: Service and Repair Body Side Molding Replacement Tools Required J 25070 Heat Gun Removal Procedure 1. Remove the molding from the vehicle using the following procedure: 1. Heat the door side molding using a J 25070 . Hold the heat gun approximately 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. Important: Be careful not to scratch or chip the paint. 2. Peel the door side molding from the panel surface using a flat-bladed tool. 2. Remove all adhesive from the body panel and the back of the door side molding using a 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 3. Clean the body panel using varnish makers and painters (VMP) naphtha. Installation Procedure 1. Ensure the painted body surface in the tape contact area is clean and dry. 2. Warm the body panel with a heat lamp or heat gun, if necessary, to a temperature between 18.8-41.1°C (66-100°F). 3. Remove the tape liner from the adhesive tape. Important: Do not touch the adhesive surface. 4. Ensure that the molding is aligned with the body panel. Press the door side molding to the body panel. 5. Hand roll the door side molding to the body in order to ensure proper adhesion. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the push-pins from the inner wheelhouse liner. 4. Remove the inner wheelhouse liner from the vehicle. 5. Remove the push-pins from the outer wheelhouse liner. 6. Remove the outer wheelhouse liner (2). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 10036 1. Install the outer wheelhouse liner (2) to the vehicle. 2. Install the rearward push-pin into the outer wheelhouse liner. 3. Install the remaining push-pins into the outer wheelhouse liner. 4. Install the inner wheelhouse liner to the vehicle. 5. Install the push-pins into the inner wheelhouse liner. 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair Pickup Box Wheelhouse Liner Replacement Removal Procedure Remove the push-in retainers that attach the liner to the vehicle. Installation Procedure Install the push-in retainers that attach the liner to the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11 > Body Underbody Squeak/Creak/Crunch Noise Body / Frame Mount Bushing: Customer Interest Body - Underbody Squeak/Creak/Crunch Noise TECHNICAL Bulletin No.: 11-08-61-001A Date: April 14, 2011 Subject: Underbody Squeak/Creak/Crunch Noise During Slow Speed Maneuvers (Replace Body Mount Cushions) Models: 2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon 2006-2010 HUMMER H3 Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 11-08-61-001 (Section 08 - Body and Accessories). Condition Some customers may comment on a squeak/creak/crunch type noise coming from under the vehicle while driving. This condition is most noticeable when driving at low speeds over uneven surfaces such as driveway entrances or in parking structures. Cause This condition may be caused by friction between the upper and lower body mount cushion assemblies. Correction A revised body mount cushion assembly is now available to correct this condition. The revised part has an anti-friction coating that will eliminate the noise. Use the following steps to diagnose the condition and install the required service part(s). To diagnose this concern, use chassis ears to determine if the noise is coming from the body mount cushion. If the source of the noise is determined to be caused by the body mount cushion, replace all of the upper body mount cushion assemblies on the vehicle with the revised parts. Use the following steps to install the revised cushion assemblies. Important On HUMMER H3 models, it is necessary to disconnect the fuel fill pipe from the fuel tank to prevent damage when lifting the body. Note On vehicles equipped with a front skid plate, it may be necessary to remove the skid plate from the vehicle to access the front mounts. 1. Disconnect the front parking brake cable from the parking brake equalizer. Refer to Parking Brake Lever Pedal Assembly Replacement in SI. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary (over 40 mm (1.57 in). Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: ^ Intermediate steering shaft - Do not allow the shaft to extend more than 25 mm (1 in). ^ Fuel tank filler hose - Do not stretch the hose excessively. ^ Tail/Turn signal lamp wiring/rear lamps junction block - Leave slack in the wires. ^ Park brake cable - Leave slack in the cable. ^ Body ground straps - Leave slack in the wire. 2. Replace all of the upper cushion assemblies on the vehicle. Refer to Drivetrain and Front Suspension Frame Insulator Replacement in SI. 3. Reconnect the front parking brake cable to the parking brake equalizer. Refer to Parking Brake Lever Pedal Assembly Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11 > Body Underbody Squeak/Creak/Crunch Noise > Page 10050 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11 > Body - Underbody Squeak/Creak/Crunch Noise Body / Frame Mount Bushing: All Technical Service Bulletins Body - Underbody Squeak/Creak/Crunch Noise TECHNICAL Bulletin No.: 11-08-61-001A Date: April 14, 2011 Subject: Underbody Squeak/Creak/Crunch Noise During Slow Speed Maneuvers (Replace Body Mount Cushions) Models: 2004-2011 Chevrolet Colorado 2004-2011 GMC Canyon 2006-2010 HUMMER H3 Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 11-08-61-001 (Section 08 - Body and Accessories). Condition Some customers may comment on a squeak/creak/crunch type noise coming from under the vehicle while driving. This condition is most noticeable when driving at low speeds over uneven surfaces such as driveway entrances or in parking structures. Cause This condition may be caused by friction between the upper and lower body mount cushion assemblies. Correction A revised body mount cushion assembly is now available to correct this condition. The revised part has an anti-friction coating that will eliminate the noise. Use the following steps to diagnose the condition and install the required service part(s). To diagnose this concern, use chassis ears to determine if the noise is coming from the body mount cushion. If the source of the noise is determined to be caused by the body mount cushion, replace all of the upper body mount cushion assemblies on the vehicle with the revised parts. Use the following steps to install the revised cushion assemblies. Important On HUMMER H3 models, it is necessary to disconnect the fuel fill pipe from the fuel tank to prevent damage when lifting the body. Note On vehicles equipped with a front skid plate, it may be necessary to remove the skid plate from the vehicle to access the front mounts. 1. Disconnect the front parking brake cable from the parking brake equalizer. Refer to Parking Brake Lever Pedal Assembly Replacement in SI. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary (over 40 mm (1.57 in). Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: ^ Intermediate steering shaft - Do not allow the shaft to extend more than 25 mm (1 in). ^ Fuel tank filler hose - Do not stretch the hose excessively. ^ Tail/Turn signal lamp wiring/rear lamps junction block - Leave slack in the wires. ^ Park brake cable - Leave slack in the cable. ^ Body ground straps - Leave slack in the wire. 2. Replace all of the upper cushion assemblies on the vehicle. Refer to Drivetrain and Front Suspension Frame Insulator Replacement in SI. 3. Reconnect the front parking brake cable to the parking brake equalizer. Refer to Parking Brake Lever Pedal Assembly Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 11-08-61-001A > Apr > 11 > Body - Underbody Squeak/Creak/Crunch Noise > Page 10056 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 10057 Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement Removal Procedure Support the frame with the hoist when you change the body mounts. If only one mount is changed, loosen and lower the entire side on which the mount in question is being replaced. 1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Use jack stands or the equivalent to support the body where the mounts will be replaced. 3. Remove the bolt/cushion assembly at the number 1 and the number 2 body mount. 4. Remove the bolt/cushion assembly at the number 3 body mount, short wheel base vehicles. 5. Remove the bolt/cushion assembly at the number 3 and the number 4 body mount, long wheel base vehicles. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 10058 6. Disconnect or remove any wiring harness or component that may interfere with the lowering of the frame. 7. Lower the hoist in order to leave the body supported by the jack stands. 8. Remove the upper cushions at the number 1 and the number 2 body mount. 9. Remove the upper cushions at the number 3 body mount, short wheel base vehicles. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 10059 10. Remove the upper cushions at the number 3 and the number 4 body mount, long wheel base vehicles. Installation Procedure 1. Install the upper cushions to the number 3 and the number 4 body mount, long wheel base vehicles. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 10060 2. Install the upper cushion to the number 3 body mount, short wheel base vehicles. 3. Install the upper cushions to the number 1 and the number 2 body mount. 4. Raise the hoist to allow the body mount bolts to be installed. 5. Connect or install any wiring harness or component that was removed to allow for the lowering of the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 10061 6. Install the bolt/cushion assembly to the number 1 and the number 2 body mount. 7. Install the bolt/cushion assembly to the number 3 body mount, short wheel base vehicles. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the bolt/cushion assembly to the number 3 and the number 4 body mount, long wheel base vehicles. Tighten the bolts to 115 Nm (85 lb ft). 9. Remove the jack stands. 10. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement Cross-Member: Service and Repair Crossmember Replacement Crossmember Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the crossmember mounting nuts and bolts. 3. Remove the crossmember from the vehicle. Installation Procedure 1. Install the crossmember to the vehicle. 2. Perform the following procedure before installing the bolts. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 10066 * Remove all traces of the original adhesive patch. * Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. * Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts and the nuts and tighten to 60 Nm (44 lb ft). 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 10067 Cross-Member: Service and Repair Transmission Support Crossmember Replacement Transmission Support Crossmember Replacement (2WD) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a suitable stand or jack. 3. Remove the nuts retaining the transmission mount to the transmission support. Refer to Transmission Mount Replacement (2WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission. 4. Raise the transmission. 5. Remove the vertical bolts retaining the transmission support to the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 10068 6. Remove the horizontal nuts and the bolts retaining the transmission support to the frame. 7. Remove the transmission support from the frame. Installation Procedure 1. Install the transmission support to the frame. 2. Loose install the horizontal nuts and the bolts retaining the transmission support to the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement > Page 10069 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Loose install the vertical bolts retaining the transmission support to the frame. * Tighten the horizontal nuts to 50 Nm (37 lb ft). * Tighten the vertical bolts to 100 Nm (74 lb ft). 4. Lower the transmission. 5. Install the nuts to the transmission mount. Refer to Transmission Mount Replacement (2WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair) for the 4L60E/4L65E transmission or Transmission Mount Replacement (RPO Z71) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair )Transmission Mount Replacement (4WD) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair)Transmission Mount Replacement (RPO Z85 and ZQ8) (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair) for the Aisin AR5 transmission. 6. Remove the stand or jack. 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair Skid Plate: Service and Repair Engine Protection Shield Replacement Removal Procedure 1. Remove the front shield bolts (1, 2). 2. Remove the front shield from the vehicle. 3. Remove the rear shield bolts (1, 2). 4. Remove the rear shield from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Page 10073 1. Install the rear shield to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the rear shield bolts (1) and tighten to 75 Nm (55 lb ft). 3. Install the rear shield bolts (2) and tighten to 20 Nm (15 lb ft). 4. Install the front shield to the vehicle. 5. Install the front shield bolts (1) and tighten to 60 Nm (44 lb ft). 6. Install the front shield bolts (2) and tighten to 20 Nm (15 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Weight Distributor Hitch Platform Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair Grille Replacement Removal Procedure 1. Open the hood. 2. Release the retainer on the daytime running lights (DRL), park lamp assembly. 3. Remove the DRL, park lamp assembly. 4. Use a flat-bladed tool in order to release the retainers that retain the grille to the body. 5. Lift the grille out of position. 6. Remove the grille from the vehicle. 7. Remove the nuts retaining the grille bar (1) to the grille (2). 8. Remove the grille bar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 10080 Installation Procedure 1. Position the grille to the grille molding. 2. Using a Weller(R) model 8200 soldering gun, or equivalent, equipped with a flat tip, use a circular motion around the heat stake. 1. Apply firm steady pressure to spread the heat stake material onto the grille panel to achieve a proper weld. 2. Heat stake the grille to the grille molding at all heat stake locations. 3. Install the grille bar (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the grille bar retaining nuts. Tighten the nuts to 4 Nm (35 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 10081 5. Position the grille to the vehicle. 6. Position the grille onto the radiator support such that the lower locating tabs are properly aligned. 7. Push the lower portion of the grille rearward until an audible engagement of the retainers is heard. 8. Align the upper locating tabs of the grille with the slots in the radiator support. 9. Install and fully seat the retaining clips into the radiator support. 10. Install the DRL, park lamp assembly. 11. Lower the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle Carpet: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10087 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10088 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10089 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10090 Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10091 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10092 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10093 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 10094 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Eliminating Unwanted Odors in Vehicles Carpet: Service and Repair Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. * Instructions and cautions are printed on the bottle, but additional help is available. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Eliminating Unwanted Odors in Vehicles > Page 10097 Carpet: Service and Repair Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Eliminating Unwanted Odors in Vehicles > Page 10098 Carpet: Service and Repair Floor Panel Carpet Replacement Floor Panel Carpet Replacement Removal Procedure 1. Remove the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 2. Remove the rear seats, if equipped. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). 3. Remove the storage bins, if equipped. Refer to Rear Storage Compartment Replacement (See: Utility Storage Compartment/Service and Repair). 4. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. For extended and crew cabs, remove the jack tools from the floor. 6. Remove the floor console, if equipped. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Console/Service and Repair )Console Replacement (Small w/Manual Transmission) (See: Console/Service and Repair). 7. Remove the lower center instrument panel (I/P) trim. Refer to Instrument Panel Lower Center Trim Replacement (See: Dashboard / Instrument Panel/Service and Repair). 8. Remove the front door sill plates. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 9. Remove the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Left Side (See: Trim Panel/Service and Repair). 10. Remove the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement Right Side (See: Trim Panel/Service and Repair). 11. Remove the rear door sill plates, if equipped. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 12. Remove the lower center pillar trim panels, if equipped. Refer to Center Pillar Lower Trim Panel Replacement (See: Trim Panel/Service and Repair). 13. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 14. Remove the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 15. Remove the carpet from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Eliminating Unwanted Odors in Vehicles > Page 10099 1. Position the carpet in the vehicle. 2. Install the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 3. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 4. Install the lower center pillar trim panels, if equipped. Refer to Center Pillar Lower Trim Panel Replacement (See: Trim Panel/Service and Repair ). 5. Install the rear door sill plates, if equipped. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 6. Install the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Left Side (See: Trim Panel/Service and Repair). 7. Install the right hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement - Right Side (See: Trim Panel/Service and Repair). 8. Install the front door sill plates. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 9. Install the lower center I/P trim. Refer to Instrument Panel Lower Center Trim Replacement (See: Dashboard / Instrument Panel/Service and Repair). 10. Install the floor console, if equipped. Refer to Console Replacement (Large w/Manual or Auto Transmission) (See: Console/Service and Repair )Console Replacement (Small w/Manual Transmission) (See: Console/Service and Repair). 11. For extended and crew cabs, install the jack tools to the floor. 12. Install the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 13. Install the storage bins, if equipped. Refer to Rear Storage Compartment Replacement (See: Utility Storage Compartment/Service and Repair). 14. Install the rear seats, if equipped. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). 15. Install the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) Console: Service and Repair Console Replacement (Large w/Manual or Auto Transmission) Console Replacement (Large w/Manual or Auto Transmission) Removal Procedure 1. For regular cab vehicles, remove the passenger front bucket seat. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 2. For regular, extended and crew cab vehicles, remove the front bucket seat fasteners retaining the floor console to the floor. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 3. If the vehicle is equipped with a floor mounted shift lever, remove the shift lever bezel and boot. 4. Lift upward on the front and middle section of the console to release the retainers. 5. Remove the console from the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10104 Installation Procedure 1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding holes in the floor panel. Important: Ensure the console bracket is positioned under the seat frame. 3. Push downward on the console to seat the retainers. 4. If the vehicle is equipped with a floor mounted shift lever, install the shift lever bezel and boot. 5. Install the console bolts and if necessary, install the front bucket seat. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10105 Console: Service and Repair Console Replacement (Small w/Manual Transmission) Console Replacement (Small w/Manual Transmission) Removal Procedure 1. Release the retaining strips on the shift lever boot. 2. Remove the inside rear seat track bolts on both front seats. 3. Lift up on the console to release the 4 retainers. 4. Remove the console from the vehicle. Installation Procedure 1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding holes in the floor panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10106 3. Push downward on the console seating the retainers. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the seat track bolts on both front seats. Tighten the bolts to 53 Nm (39 lb ft). 5. Attach the retaining strips on the shift lever bezel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10107 Console: Service and Repair Console Shift Lever Bezel Replacement Console Shift Lever Bezel Replacement Removal Procedure 1. Separate the retaining strips on the shift lever boot. 2. Lift upward on the shift lever bezel to release the retaining tabs. 3. Lift the bezel and boot over the shift lever. 4. If necessary, remove the boot assembly from the bezel by releasing the wire retainer and position locator (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10108 1. If necessary, install the boot to the bezel ensuring the position locator (1) is pointing forward. 2. Lower the bezel and boot over the shift lever. 3. Ensure the retaining tabs are properly indexed to the console. 4. Push downward on the shift lever bezel to seat the retaining tabs. 5. Attach the retaining strips on the shift lever boot. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10109 Console: Service and Repair Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Removal Procedure 1. Open the console armrest, revealing the lower compartment. 2. Remove the 3 screws (1) located on the upper hinge. 3. Remove the armrest from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10110 1. Position the armrest to the console. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 screws (1) retaining the armrest to the upper hinge. Tighten the screws to 1.5 Nm (15 lb in). 3. Close the armrest. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10111 Console: Service and Repair Console Replacement (Large w/Manual or Auto Transmission) Console Replacement (Large w/Manual or Auto Transmission) Removal Procedure 1. For regular cab vehicles, remove the passenger front bucket seat. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 2. For regular, extended and crew cab vehicles, remove the front bucket seat fasteners retaining the floor console to the floor. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 3. If the vehicle is equipped with a floor mounted shift lever, remove the shift lever bezel and boot. 4. Lift upward on the front and middle section of the console to release the retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10112 5. Remove the console from the vehicle. Installation Procedure 1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding holes in the floor panel. Important: Ensure the console bracket is positioned under the seat frame. 3. Push downward on the console to seat the retainers. 4. If the vehicle is equipped with a floor mounted shift lever, install the shift lever bezel and boot. 5. Install the console bolts and if necessary, install the front bucket seat. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). Console Replacement (Small w/Manual Transmission) Console Replacement (Small w/Manual Transmission) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10113 1. Release the retaining strips on the shift lever boot. 2. Remove the inside rear seat track bolts on both front seats. 3. Lift up on the console to release the 4 retainers. 4. Remove the console from the vehicle. Installation Procedure 1. Position the console to the floor panel. 2. Ensure the retainers are indexed to the corresponding holes in the floor panel. 3. Push downward on the console seating the retainers. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the seat track bolts on both front seats. Tighten the bolts to 53 Nm (39 lb ft). 5. Attach the retaining strips on the shift lever bezel. Console Shift Lever Bezel Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10114 Console Shift Lever Bezel Replacement Removal Procedure 1. Separate the retaining strips on the shift lever boot. 2. Lift upward on the shift lever bezel to release the retaining tabs. 3. Lift the bezel and boot over the shift lever. 4. If necessary, remove the boot assembly from the bezel by releasing the wire retainer and position locator (1). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10115 1. If necessary, install the boot to the bezel ensuring the position locator (1) is pointing forward. 2. Lower the bezel and boot over the shift lever. 3. Ensure the retaining tabs are properly indexed to the console. 4. Push downward on the shift lever bezel to seat the retaining tabs. 5. Attach the retaining strips on the shift lever boot. Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Removal Procedure 1. Open the console armrest, revealing the lower compartment. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10116 2. Remove the 3 screws (1) located on the upper hinge. 3. Remove the armrest from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10117 1. Position the armrest to the console. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 screws (1) retaining the armrest to the upper hinge. Tighten the screws to 1.5 Nm (15 lb in). 3. Close the armrest. Front Floor Console Compartment Door Hinge Replacement Front Floor Console Compartment Door Hinge Replacement Removal Procedure 1. Remove the armrest. Refer to Front Floor Console Armrest Replacement (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10118 2. Remove the 3 screws (2) located on the lower hinge. 3. Remove the hinge from the vehicle. Installation Procedure 1. Position the hinge to the console. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 screws (2) retaining the armrest to the lower hinge. Tighten the screws to 1.5 Nm (15 lb in). 3. Install the armrest. Refer to Front Floor Console Armrest Replacement (See: ). Front Floor Console Storage Tray Replacement Front Floor Console Storage Tray Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement (Large w/Manual or Auto Transmission) > Page 10119 Removal Procedure 1. Ensure the console tray is empty. 2. Lift upward on the console tray to release the retaining tabs. 3. Remove the console tray from the vehicle. Installation Procedure 1. Position the tray to the console. 2. Ensure the retaining tabs are indexed to the corresponding holes in the console. 3. Push downward on the tray seating the retaining tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 10124 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Door Latch Replacement Glove Compartment: Service and Repair Instrument Panel Compartment Door Latch Replacement Instrument Panel Compartment Door Latch Replacement Removal Procedure 1. Open the instrument panel (I/P) storage compartment. 2. Remove the screws retaining the storage compartment handle assembly. 3. Remove the handle assembly from the vehicle. Installation Procedure 1. Install the handle assembly the storage compartment. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10129 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws retaining the handle assembly to the storage compartment. Tighten the screws to 3 Nm (27 lb in). 3. Ensure the handle assembly is working properly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10130 Glove Compartment: Service and Repair Instrument Panel Compartment Door Replacement Instrument Panel Compartment Door Replacement Removal Procedure 1. Remove the instrument panel (I/P) storage compartment assembly. Refer to Instrument Panel Storage Compartment Replacement (See: Dashboard / Instrument Panel/Service and Repair). 2. Remove the screws retaining the storage compartment back panel. 3. Remove the back panel from the storage compartment. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10131 1. Install the back panel to the storage compartment. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws retaining the storage compartment back panel. Tighten the screws to 3 Nm (27 lb in). 3. Install the instrument panel (I/P) storage compartment assembly. Refer to Instrument Panel Storage Compartment Replacement (See: Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10132 Glove Compartment: Service and Repair Instrument Panel Storage Compartment Replacement Instrument Panel Storage Compartment Replacement Removal Procedure 1. Remove the screws retaining the instrument panel (I/P) compartment assembly to the I/P. 2. Open the I/P compartment door. 3. Remove the I/P compartment assembly from the vehicle. Installation Procedure 1. Position the I/P compartment assembly to the I/P. 2. Close and fully latch the I/P compartment door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Door Latch Replacement > Page 10133 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fasteners retaining the I/P compartment assembly to the I/P. Tighten the fasteners to 3 Nm (27 lb in). 4. Ensure the alignment of the door allows for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) Headliner: Service and Repair Headlining Trim Panel Replacement (Crew Cab) Headlining Trim Panel Replacement (Crew Cab) Warning Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Caution: Use care when working around the head curtain inflator module. Sharp tools may puncture the curtain airbag. If the head curtain inflator module is damaged in any way, it must be replaced. Caution: If a vehicle is equipped with a head curtain inflator module ensure that the inflator module and tether are undamaged. If tether or curtain airbag are damaged in any way, they must be replaced. Removal Procedure 1. Remove the right front door. Refer to Front Side Door Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Service and Repair). 2. Remove the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 3. Remove the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). 4. Remove the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and Repair). 5. Disconnect the headliner harness (1) from the body harness (2). 6. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Trim Panel/Service and Repair). 7. Remove the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (See: Trim Panel/Service and Repair). 8. Remove the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 9. Remove the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair). 10. Remove the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service and Repair). 11. Remove the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 12. Remove the assist handles and the driver assist handle or assist handle blank. Refer to Assist Handle Replacement (See: Passenger Assist Handle/Service and Repair). 13. Remove the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10138 14. Tilt the steering wheel to the full down position. 15. If equipped with a manual transmission, place the transmission in 2nd gear and remove the shift knob handle. 16. Remove the 2 push pins securing the headliner to the row bow. 17. Remove the 2 rear push pins from the headliner. Replace any damaged push pin spacers. 18. Lower the forward edge of the headliner. 19. Standing at the left front door, grasp the headliner at the dome lamp opening and at the headliner's left edge. 20. Slide the headliner forward and under the steering wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10139 21. Rotate the forward edge of the headliner towards the right front door opening ensuring that the left edge of the headliner is behind the shift knob stem. 22. Remove the headliner from the vehicle through the right front door opening. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10140 1. Install the headliner in the vehicle through the right front door opening, rear edge first. 2. Slid the headliner into the vehicle towards the left side of the cab ensuring that the left edge of the headliner is behind the shift knob stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10141 3. Rotate the rear edge of the headliner towards the rear of the cab with the forward edge of the headliner under the steering wheel. 4. Ensure that the roof rail air bag tethers will not be obstructed by the installed headliner. 5. Raise the headliner into position and install the 2 rear push pins into the roof. 6. Install the 2 push pins securing the headliner to the row bow. 7. Install the headliner above the door weather strips. 8. Install the inboard sunshade retainers. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 9. Install the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 10. Install the assist handles and the driver assist handle or assist handle blank. Refer to Assist Handle Replacement (See: Passenger Assist Handle/Service and Repair). 11. Install the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair). 12. Install the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service and Repair). 13. Install the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair). 14. Install the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 15. Install the upper center pillar trim panel. Refer to Center Pillar Upper Trim Panel Replacement (See: Trim Panel/Service and Repair). 16. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10142 17. Connect the headliner harness (1) to the body harness (2). 18. Install the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and Repair). 19. Install the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). 20. Install the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 21. Install the right front door. Refer to Front Side Door Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10143 Headliner: Service and Repair Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Extended Cab) Warning Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Caution: Use care when working around the head curtain inflator module. Sharp tools may puncture the curtain airbag. If the head curtain inflator module is damaged in any way, it must be replaced. Caution: If a vehicle is equipped with a head curtain inflator module ensure that the inflator module and tether are undamaged. If tether or curtain airbag are damaged in any way, they must be replaced. Removal Procedure 1. Remove the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and Repair). 2. Disconnect the headliner harness (1) from the body harness (2). 3. Remove the rear door striker trim cover. Refer to Rear Side Door Latch Striker Cover Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 4. Remove the rear seat back cushions. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 5. Remove the rear folding seats. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 6. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 7. Remove the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 8. Remove the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair). 9. Remove the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service and Repair). 10. Remove the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 11. Remove the passenger assist handle and the driver assist handle or assist handle blank. Refer to Assist Handle Replacement (See: Passenger Assist Handle/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10144 12. Remove the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair). 13. Tilt the steering wheel to the full down position. 14. If equipped with a manual transmission, place the transmission in 2nd gear and remove the shift knob handle. 15. Remove the 2 push pins securing the headliner to the row bow. 16. Remove the 2 rear push pins from the headliner. Replace any damaged push pin spacers. 17. Lower the forward edge of the headliner. 18. Standing at the left front door, grasp the headliner at the dome lamp opening and at the headliner's left edge. 19. Slide the headliner forward and under the steering wheel. 20. Rotate the forward edge of the headliner towards the right-hand door opening. 21. Remove the headliner from the vehicle through the door opening. Installation Procedure 1. Install the headliner in the vehicle through the right-hand door opening, rear edge first. 2. Slid the headliner into the vehicle towards the left side of the cab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10145 3. Rotate the rear edge of the headliner towards the rear of the cab with the forward edge of the headliner under the steering wheel. 4. Ensure that the roof rail air bag tethers will not be obstructed by the installed headliner. 5. Raise the headliner into position and install the 2 rear push pins into the roof. 6. Install the 2 push pins securing the headliner to the row bow. 7. Install the headliner above the door weather strips. 8. Install the inboard sunshade retainers. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 9. Install the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 10. Install the passenger assist handle and the driver assist handle or assist handle blank. Refer to Assist Handle Replacement (See: Passenger Assist Handle/Service and Repair). 11. Install the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair). 12. Install the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service and Repair). 13. Install the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair). 14. Install the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 15. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Rear Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 16. Install the rear folding seats. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 17. Install the rear seat back cushions. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 18. Install the rear door striker trim cover. Refer to Rear Side Door Latch Striker Cover Replacement (Extended Cab) (See: Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10146 19. Connect the headliner harness (1) to the body harness (2). 20. Install the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10147 Headliner: Service and Repair Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Regular Cab) Warning Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Caution: Use care when working around the head curtain inflator module. Sharp tools may puncture the curtain airbag. If the head curtain inflator module is damaged in any way, it must be replaced. Caution: If a vehicle is equipped with a head curtain inflator module ensure that the inflator module and tether are undamaged. If tether or curtain airbag are damaged in any way, they must be replaced. Removal Procedure 1. Remove the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 2. Remove the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and Repair). 3. Disconnect the headliner harness (1) from the body harness (2). 4. Remove the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). 5. Remove the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair). 6. Remove the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service and Repair). 7. Remove the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 8. Remove the passenger assist handle and the driver assist handle or assist handle blank. Refer to Assist Handle Replacement (See: Passenger Assist Handle/Service and Repair). 9. Remove the coat hook. Refer to Coat Hook Replacement (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10148 10. Tilt the steering wheel to the full down position. 11. If equipped with a manual transmission, place the transmission in 2nd gear and remove the shift knob handle. 12. Remove the 2 push pins securing the headliner to the row bow. 13. Remove the rear push pin from the headliner. Replace any damaged push pin spacers. 14. Lower the forward edge of the headliner. 15. Standing at the left front door, grasp the headliner at the dome lamp opening and at the headliner left edge. 16. Slide the headliner forward and under the steering wheel. 17. Rotate the forward edge of the headliner towards the right-hand door opening. 18. Remove the headliner from the vehicle through the door opening. Installation Procedure 1. Install the headliner in the vehicle through the right-hand door opening, rear edge first. 2. Slide the headliner into the vehicle towards the left side of the cab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10149 3. Rotate the rear edge of the headliner towards the rear of the cab with the forward edge of the headliner under the steering wheel. 4. Ensure that the roof rail air bag tethers will not be obstructed by the installed headliner. 5. Raise the headliner into position and install the rear push pin into the roof. 6. Install the 6 push pins securing the headliner to the row bow. 7. Install the headliner above the door weather strips. 8. Install the inboard sunshade retainers. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 9. Install the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair). 10. Install the passenger assist handle and the driver assist handle or assist handle blank. Refer to Assist Handle Replacement (See: Passenger Assist Handle/Service and Repair). 11. Install the coat hook. Refer to Coat Hook Replacement (See: Service and Repair). 12. Install the dome lamp. Refer to Dome Lamp Replacement (See: Lighting and Horns/Dome Lamp/Service and Repair). 13. Install the upper body rear corner trim panels. Refer to Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) (See: Trim Panel/Service and Repair)Body Side Upper Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair). 14. Install the lower body rear corner trim panels. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: Trim Panel/Service and Repair)Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Crew Cab) > Page 10150 15. Connect the headliner harness (1) to the body harness (2). 16. Install the windshield garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Trim Panel/Service and Repair). 17. Install the front seats. Refer to Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair Assist Handle Replacement Removal Procedure 1. Pull down the assist handle to reveal the 2 service holes. 2. Remove the screws and washers securing the assist handle to the retaining clip. 3. Remove the assist handle from the vehicle. 4. If replacing the entire assist handle assembly, Remove the retaining clips from the sheet metal. Installation Procedure 1. Position the assist handle over the retaining clips. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Page 10154 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the assist handle by installing 2 screws and washers into the retaining clips. Tighten the assist handle screws to 1.2 Nm (10 lb in). 3. In replacing the entire coat hook assembly, press the coat hook and the retaining clip as an assembly into the sheet metal opening until the clip locks into position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement Front Side Door Sill Trim Plate Replacement Removal Procedure 1. Grasp the front door sill plate and pull the panel away from the body to release the fasteners. 2. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 3. Slide the plate inward so the plate unhooks from the door frame. 4. Remove the front door sill plate from the vehicle. Installation Procedure 1. Position the front door sill plate over the pillar and door sill. 2. Ensure that the sill plate fasteners are aligned with the holes in the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement > Page 10159 3. Install the sill plate by pushing firmly against the body to seat the fasteners. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement > Page 10160 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement Rear Side Door Sill Trim Plate Replacement Removal Procedure 1. Grasp the rear door sill plate and pull the panel away from the body to release the fasteners. 2. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 3. Slide the plate inward so the plate unhooks from the door frame. 4. Remove the rear door sill plate from the vehicle. Installation Procedure 1. Position the rear door sill plate over the pillar and door sill. 2. Ensure that the sill plate fasteners are aligned with the holes in the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement > Page 10161 3. Install the sill plate by pushing firmly against the body to seat the fasteners. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair Sunshade Replacement Removal Procedure 1. Remove the 2 screws and washers (4) securing the sunshade (1) to the roof. 2. Remove the sunshade assembly. 3. Remove the screw and washer (3) securing the sunshade retainer (2) to the roof. 4. Remove the sunshade retainer. Installation Procedure 1. Install the sunshade retainer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Page 10165 2. Install the screw and washer (3) securing the sunshade retainer (2) to the roof. Tighten the sunshade retainer screw to 1.2 Nm (10 lb in). 3. Install the sunshade assembly to the roof with 2 screws and washers. Tighten the sunshade screws to 1.2 Nm (10 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement - Left Side Body Hinge Pillar Trim Panel Replacement - Left Side Removal Procedure 1. Remove the left front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 2. Grasp the left hinge pillar trim panel and gently pull the panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the panel unhooks from around the front door frame. 5. Remove the left hinge pillar trim panel from the vehicle. Installation Procedure 1. Position the left hinge pillar trim panel over the pillar and door sill. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10170 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the left front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10171 Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement - Right Side Body Hinge Pillar Trim Panel Replacement - Right Side Removal Procedure 1. Remove the right front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 2. Grasp the right hinge pillar trim panel and gently pull the panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the panel unhooks from around the front door frame. 5. Remove the right hinge pillar trim panel from the vehicle. Installation Procedure 1. Position the right hinge pillar trim panel over the pillar and door sill. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10172 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the right front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10173 Trim Panel: Service and Repair Body Rear Trim Panel Replacement (Crew Cab) Body Rear Trim Panel Replacement (Crew Cab) Removal Procedure 1. Remove the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). 2. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 3. Remove the rear shoulder belt guide. 4. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet metal. 5. Raise the panel to unhook it from the sheet metal along the lower edge of the rear window. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 7. Remove the body rear trim panel from the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10174 Installation Procedure 1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2. Install the panel by pushing firmly against the body to seat the panel fasteners. 3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10175 Trim Panel: Service and Repair Body Rear Trim Panel Replacement (Extended Cab) Body Rear Trim Panel Replacement (Extended Cab) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 2. Remove the folding seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 3. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 4. Remove the rear shoulder belt guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10176 5. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet metal. 6. Raise the panel to unhook it from the sheet metal along the lower edge of the rear window. 7. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 8. Remove the body rear trim panel from the vehicle. Installation Procedure 1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2. Install the panel by pushing firmly against the body to seat the panel fasteners. 3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the folding seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 6. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10177 Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement - Left Side Body Hinge Pillar Trim Panel Replacement - Left Side Removal Procedure 1. Remove the left front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 2. Grasp the left hinge pillar trim panel and gently pull the panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the panel unhooks from around the front door frame. 5. Remove the left hinge pillar trim panel from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10178 1. Position the left hinge pillar trim panel over the pillar and door sill. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the left front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). Body Hinge Pillar Trim Panel Replacement - Right Side Body Hinge Pillar Trim Panel Replacement - Right Side Removal Procedure 1. Remove the right front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 2. Grasp the right hinge pillar trim panel and gently pull the panel away from the body to release the fasteners. 3. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 4. Slide the panel forward so the panel unhooks from around the front door frame. 5. Remove the right hinge pillar trim panel from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10179 1. Position the right hinge pillar trim panel over the pillar and door sill. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the right front door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). Body Rear Trim Panel Replacement (Crew Cab) Body Rear Trim Panel Replacement (Crew Cab) Removal Procedure 1. Remove the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). 2. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 3. Remove the rear shoulder belt guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10180 4. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet metal. 5. Raise the panel to unhook it from the sheet metal along the lower edge of the rear window. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 7. Remove the body rear trim panel from the vehicle. Installation Procedure 1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2. Install the panel by pushing firmly against the body to seat the panel fasteners. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10181 3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). Body Rear Trim Panel Replacement (Extended Cab) Body Rear Trim Panel Replacement (Extended Cab) Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 2. Remove the folding seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 3. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10182 4. Remove the rear shoulder belt guide. 5. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet metal. 6. Raise the panel to unhook it from the sheet metal along the lower edge of the rear window. 7. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 8. Remove the body rear trim panel from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10183 1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2. Install the panel by pushing firmly against the body to seat the panel fasteners. 3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Install the folding seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 6. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). Body Rear Trim Panel Replacement (Regular Cab) Body Rear Trim Panel Replacement (Regular Cab) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10184 1. Remove the front seats. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement). 2. Remove the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 3. Remove the rear shoulder belt guide. 4. Grasp the lower edge of the body rear trim panel and pull to release the fasteners from the sheet metal. 5. Raise the panel to unhook it from the sheet metal along the lower edge of the rear window. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 7. Remove the body rear trim panel from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10185 1. Hook the body rear trim panel in the sheet metal along the lower edge of the rear window. 2. Install the panel by pushing firmly against the body to seat the panel fasteners. 3. Install the rear shoulder belt guide. 4. Install the jack and tool storage bracket. Refer to Jack and Tool Stowage Container Bracket Replacement (See: Jack/Service and Repair). 5. Remove the front seats. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Seats/Service and Repair/Split Bench Seat Replacement). Body Side Rear Lower Trim Panel Replacement (Crew Cab) Body Side Rear Lower Trim Panel Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 2. Remove the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10186 3. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel Replacement (Regular Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ). 4. Grasp the lower body rear corner trim panel and gently pull the panel (1) away from the body to release the fasteners. 5. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 6. Slide the panel forward so the panel unhooks from around the rear door frame. 7. Remove the lower body rear corner trim panel from the vehicle. Installation Procedure 1. Position the lower body rear corner trim panel (1) so that the front edge hooks around the rear door frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel Replacement (Regular Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ). 5. Install the rear seat. Refer to Rear Bench Seat Replacement (See: Seats/Service and Repair/Rear Bench Seat Replacement). 6. Install the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10187 Body Side Rear Lower Trim Panel Replacement (Extended Cab) Body Side Rear Lower Trim Panel Replacement (Extended Cab) Removal Procedure 1. Remove the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 2. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 3. Remove the rear folding seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 4. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel Replacement (Regular Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ). 5. Grasp the lower body rear corner trim panel and gently pull the panel away from the body to release the fasteners. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 7. Slide the panel forward so the panel unhooks from around the door frame. 8. Remove the lower body rear corner trim panel from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10188 1. Position the lower body rear corner trim panel so that the front edge hooks around the door frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel Replacement (Regular Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ). 5. Install the rear folding seat. Refer to Folding Seat Replacement (Extended Cab) (See: Seats/Service and Repair/Folding Seat Replacement (Extended Cab)). 6. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seats/Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 7. Install the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). Body Side Rear Lower Trim Panel Replacement (Regular Cab) Body Side Rear Lower Trim Panel Replacement (Regular Cab) Removal Procedure 1. Remove the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). 2. Remove the front seat. Refer to Front Seat Replacement Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 3. Remove the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel Replacement (Regular Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10189 4. Grasp the lower body rear corner trim panel and gently pull the panel away from the body to release the fasteners. 5. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 6. Slide the panel forward so the panel unhooks from around the door frame. 7. Remove the lower body rear corner trim panel from the vehicle. Installation Procedure 1. Position the lower body rear corner trim panel so that the front edge hooks around the door frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the body rear trim panel. Refer to Body Rear Trim Panel Replacement (Crew Cab) (See: )Body Rear Trim Panel Replacement (Regular Cab) (See: )Body Rear Trim Panel Replacement (Extended Cab) (See: ). 5. Remove the front seat. Refer to Front Seat Replacement - Bucket (See: Seats/Service and Repair/Front Seat Replacement - Bucket). 6. Install the rear door sill plates. Refer to Rear Side Door Sill Trim Plate Replacement (See: Scuff Plate/Service and Repair). Body Side Upper Trim Panel Replacement (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10190 Body Side Upper Trim Panel Replacement (Crew Cab) Removal Procedure 1. Remove the lower body rear corner trim panel (1). Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: ). 2. Remove the upper anchor bolt for the rear seat belt. Refer to Rear Seat Belt Replacement (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Rear Seat Belt Replacement). 3. Remove the seat belt adjuster knob. 4. Remove the trim plate (2). 5. Remove the bolt securing the roof rail air bag tether (4). 6. Grasp the top of the upper body rear corner trim panel (3) and gently pull the panel away from the body to release the fasteners. 7. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 8. Remove the upper body rear corner trim panel from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10191 1. Position the upper body rear corner trim panel (3). 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the upper body rear corner trim panel (3) by pushing firmly against the body to seat the panel fasteners. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolt securing the roof rail air bag tether (4). Ensure that the tether strap is not twisted. Tighten the roof rail air bag tether bolt to 9 Nm (79 lb in). 5. Install the trim plate (2). 6. Install the seat belt adjuster knob. 7. Install the upper anchor bolt for the front seat belt. Refer to Rear Seat Belt Replacement (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Rear Seat Belt Replacement). 8. Install the lower body rear corner trim panel (1). Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: ). Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) Body Side Upper Trim Panel Replacement (Regular Cab, Extended Cab) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10192 1. Remove the lower body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: ). 2. Remove the upper anchor bolt for the rear seat belt. Refer to Rear Seat Belt Replacement (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Rear Seat Belt Replacement). 3. Remove the seat belt adjuster knob. 4. Remove the trim plate. 5. Grasp the top of the upper body rear corner trim panel and gently pull the panel away from the body to release the fasteners. 6. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 7. Remove the upper body rear corner trim panel from the vehicle. Installation Procedure 1. Position the upper body rear corner trim panel. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the upper body rear corner trim panel by pushing firmly against the body to seat the panel fasteners. 4. Install the trim plate. 5. Install the seat belt adjuster knob. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10193 6. Install the upper anchor bolt for the front seat belt. Refer to Rear Seat Belt Replacement (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Rear Seat Belt Replacement). 7. Install the lower body rear corner trim panel. Refer to Body Side Rear Lower Trim Panel Replacement (Regular Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Crew Cab) (See: )Body Side Rear Lower Trim Panel Replacement (Extended Cab) (See: ). Center Pillar Lower Trim Panel Replacement Center Pillar Lower Trim Panel Replacement Removal Procedure 1. Grasp the lower center pillar trim panel and gently pull the panel away from the body to release the fasteners. 2. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 3. Slide the panel forward so the panel unhooks from around the front door frame. 4. Remove the lower center pillar trim panel from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10194 1. Position the lower center pillar trim panel so that the front edge hooks around the front door frame. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. Center Pillar Upper Trim Panel Replacement Center Pillar Upper Trim Panel Replacement Removal Procedure 1. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: ). 2. Remove the upper anchor bolt for the front seat belt. Refer to Front Seat Belt Replacement (Crew Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt Replacement (Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Regular and Extended Cab)). 3. Remove the seat belt adjuster knob. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10195 4. Grasp the top of the upper center pillar trim panel and gently pull the panel away from the body to release the fasteners. 5. Remove any fasteners that may have pulled away from the panel and reinstall them to the back of the panel. 6. Remove the upper center pillar trim panel from the vehicle. Installation Procedure 1. Position the upper center pillar trim panel. 2. Ensure that the panel fasteners are aligned with the holes in the body. 3. Install the panel by pushing firmly against the body to seat the panel fasteners. 4. Install the seat belt adjuster knob. 5. Install the upper anchor bolt for the front seat belt. Refer to Front Seat Belt Replacement (Crew Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Crew Cab))Front Seat Belt Replacement (Regular and Extended Cab) (See: Restraint Systems/Seat Belt Systems/Seat Belt/Service and Repair/Front Seat Belt Replacement (Regular and Extended Cab)). 6. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: ). Jack Stowage Cover Replacement Jack Stowage Cover Replacement Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10196 1. Remove the screw securing the jack cover to the jack stowage bracket. 2. Remove the jack cover by lifting up to release the tab from behind the jack stowage bracket. Installation Procedure 1. Position the jack cover over the jack stowage bracket ensuring that the tab on the rear of the cover hooks behind the top of the jack stowage bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screw securing the jack cover to the jack stowage bracket. Tighten the jack cover screw until fully seated, tight, but not stripped. Rear Side Door Latch Striker Cover Replacement (Extended Cab) Rear Side Door Latch Striker Cover Replacement (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10197 Removal Procedure 1. Open the rear door. 2. Grasp the weatherstrip and gently pull the weatherstrip away from the door opening near the trim cover. 3. Remove the push-pin securing the cover to the vehicle. 4. Remove the trim cover. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10198 1. Position the trim cover (3) to the vehicle ensuring that the retaining tabs (2) are properly engaged to the headliner (1). 2. Install the push-pin securing the trim cover to the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10199 3. Install the weatherstrip by pushing it firmly back into place. 4. Close the rear door. Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement Removal Procedure 1. Remove the bolt cover (1) using a flat-bladed plastic tool. 2. Remove the windshield garnish molding bolt (3) securing the molding to the pillar. 3. Remove the windshield garnish molding by pulling the molding away from the pillar. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement - Left Side > Page 10200 1. Position the windshield garnish molding on the pillar. 2. Install the molding by firmly pressing the molding against the pillar to seat the fasteners (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the windshield garnish molding bolt (3). Tighten the bolt to 9 Nm (79 lb in). 4. Install the bolt cover (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Technical Service Bulletins > Customer Interest for Utility Storage Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken Utility Storage Compartment Latch: Customer Interest Interior - Rear Storage Area Latch Separated/Broken TECHNICAL Bulletin No.: 09-08-110-018A Date: October 21, 2010 Subject: Rear Storage Compartment Latch Separated or Broken (Replace Latch) Models: 2006-2009 Chevrolet Colorado 2006-2009 GMC Canyon Supercede: This bulletin is being revised to remove the Warranty Parts Center Parts Request Form and add Parts Information. Please discard Corporate Bulletin Number 09-08-110-018 (Section 08 Body and Accessories). Condition Some customers may comment that one or both of the rear storage compartment latches have separated or broken from the housing. Cause This condition may be caused by the storage compartment latch rivets pulling out of the housing, which may also cause the latch to break. Correction Replace the storage compartment latch with a revised latch using the procedure below. Important Use caution when drilling out the rivets. Do not enlarge the holes in the compartment lid. 1. Remove any remaining broken latch components (1) from the storage compartment. Drill out the rivets from remaining broken parts if required. 2. Inspect the storage compartment lid for damage or cracks around the latch mounting surface (1). Replace the storage compartment if damage is evident. Refer to Rear Storage Compartment Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Technical Service Bulletins > Customer Interest for Utility Storage Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken > Page 10210 Important Use only a 1/8 in diameter by 5/8 in long pop rivet with a 1/8 in inside diameter by 3/8 in outside diameter back-up washer to install the latch. 3. Install the revised latch using a 1/8 in diameter by 5/8 in long pop rivet (1). Install the 1/8 in inside diameter by 3/8 in outside diameter back-up washer (1) when installing the rivet to ensure the rivet does not pull through. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Utility Storage Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken Utility Storage Compartment Latch: All Technical Service Bulletins Interior - Rear Storage Area Latch Separated/Broken TECHNICAL Bulletin No.: 09-08-110-018A Date: October 21, 2010 Subject: Rear Storage Compartment Latch Separated or Broken (Replace Latch) Models: 2006-2009 Chevrolet Colorado 2006-2009 GMC Canyon Supercede: This bulletin is being revised to remove the Warranty Parts Center Parts Request Form and add Parts Information. Please discard Corporate Bulletin Number 09-08-110-018 (Section 08 Body and Accessories). Condition Some customers may comment that one or both of the rear storage compartment latches have separated or broken from the housing. Cause This condition may be caused by the storage compartment latch rivets pulling out of the housing, which may also cause the latch to break. Correction Replace the storage compartment latch with a revised latch using the procedure below. Important Use caution when drilling out the rivets. Do not enlarge the holes in the compartment lid. 1. Remove any remaining broken latch components (1) from the storage compartment. Drill out the rivets from remaining broken parts if required. 2. Inspect the storage compartment lid for damage or cracks around the latch mounting surface (1). Replace the storage compartment if damage is evident. Refer to Rear Storage Compartment Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Utility Storage Compartment Latch: > 09-08-110-018A > Oct > 10 > Interior - Rear Storage Area Latch Separated/Broken > Page 10216 Important Use only a 1/8 in diameter by 5/8 in long pop rivet with a 1/8 in inside diameter by 3/8 in outside diameter back-up washer to install the latch. 3. Install the revised latch using a 1/8 in diameter by 5/8 in long pop rivet (1). Install the 1/8 in inside diameter by 3/8 in outside diameter back-up washer (1) when installing the rivet to ensure the rivet does not pull through. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Jack > Component Information > Service and Repair Jack: Service and Repair Jack and Tool Stowage Container Bracket Replacement Removal Procedure 1. Remove the jack stowage cover. Refer to Jack Stowage Cover Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 2. Remove the jack from the stowage bracket by turning the jack handle to loosen the jack. 3. Remove the 2 bolts securing the jack stowage bracket to the vehicle. Installation Procedure 1. Position the jack stowage bracket on the floor stud in the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Jack > Component Information > Service and Repair > Page 10220 2. Install the 2 bolts securing the jack stowage bracket to the vehicle. Tighten the jack stowage bracket bolts to 9 Nm (79 lb in). 3. Install the jack in the stowage bracket by positioning the jack on the 2 studs then turning the jack handle to tighten the jack in the bracket. 4. Install the jack stowage cover. Refer to Jack Stowage Cover Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement Front Side Door Lock Cylinder Replacement Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Remove the front outside door handle. Refer to Front Side Door Outside Handle Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Exterior Handle/Service and Repair). 4. Remove the bolts retaining the lock cylinder to the front outside door handle. 5. Remove the lock cylinder from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement > Page 10227 1. Install the lock cylinder to the front outside door handle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the lock cylinder to the outside door handle. Tighten the lock cylinder bolts to 9 Nm (80 lb in). 3. Install the front outside door handle. Refer to Front Side Door Outside Handle Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Exterior Handle/Service and Repair). 4. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 5. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement > Page 10228 Door Lock Cylinder: Service and Repair Rear Door Lock Cylinder Replacement Endgate Lock Cylinder Replacement Removal Procedure 1. Remove the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). 2. Disconnect the clip (1) retaining the lock rod to the lock cylinder. 3. Remove the lock rod from the retaining clip (1). 4. Remove the bolt retaining the lock cylinder to the endgate handle. 5. Remove the lock cylinder from the endgate handle. Installation Procedure 1. Code the new lock cylinder. Refer to Key and Lock Cylinder Coding (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement > Page 10229 2. Install the lock cylinder to the endgate handle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolt retaining the lock cylinder to the endgate handle. Tighten the lock cylinder bolt to 9 Nm (80 lb in). 4. Install the lock rod to the retaining clip (1). 5. Connect the clip (1) retaining the lock rod to the lock cylinder. 6. Install the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10234 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10235 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10236 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair Transmitter Programming Important: Up to 4 transmitters can be programmed. Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. The order in which the transmitters are programmed is important. The first transmitter programmed will be transmitter #1, and the second transmitter programmed will be transmitter #2. Use care to program the transmitters correctly. Important: All key fobs must be programmed each time any one fob is programmed. The scan tool must stay connected until all of the transmitters are programmed. 1. Install a scan tool and navigate to the BCM Module Setup menu. 2. Select Program Key Fobs. 3. Follow the scan tool on-screen directions. 4. When the programming operations have completed, operate the transmitter functions to verify correct system operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views Power Door Lock Actuator: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views > Page 10246 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Left Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views > Page 10247 1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear (A31) 5 - Door Lock Actuator - Left Rear (AU3) Right Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views > Page 10248 1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views > Page 10249 Power Door Lock Actuator: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views > Page 10250 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Left Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views > Page 10251 1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear Right Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Component Views > Page 10252 1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 10253 Power Door Lock Actuator: Diagrams Component Connector End Views Door Lock Actuator - Driver (AU3) Door Lock Actuator - Passenger (AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 10254 Door Lock Actuator - Left Rear (Crew Cab with AU3) Door Lock Actuator - Right Rear (Crew Cab with AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 10255 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Component Views Power Door Lock Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10260 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10261 Power Door Lock Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10262 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Right Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10263 1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door Harness) Left Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10264 1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10265 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock/Window Switch - Driver X1 (A31/AU3) Door Lock/Window Switch - Driver X2 (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10266 Door Lock/Window Switch - Passenger (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10267 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door Door Lock Switch Replacement - Driver Door Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel opening. 4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate. 7. If replacing only the switch plate, retain the switches for transfer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10270 Installation Procedure 1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the switches (2, 5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the switch plate assembly to the door trim panel with the 2 screws. Tighten the front door switch plate screws to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10271 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front Door Lock Switch Replacement - Passenger Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair Outside Rearview Mirror Motor Replacement Removal Procedure 1. Remove the mirror glass. Refer to Outside Rearview Mirror Glass Replacement (See: Service and Repair/Outside Rearview Mirror Glass Replacement). 2. Remove the screws retaining the mirror motor to the mirror housing. 3. Rotate the bottom of the mirror motor upward to disengage the mirror motor (1) from the mirror housing retainers (2). 4. Disconnect the mirror motor electrical connectors. 5. Remove the mirror motor from the mirror housing. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Page 10280 1. Position the mirror motor to the mirror housing. 2. Connect the mirror motor electrical connectors. 3. Install the mirror motor to the mirror housing by engaging the mirror motor (1) to the mirror housing retainers (2) and rotating the motor downward. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screws retaining the mirror motor to the mirror housing. Tighten the mirror motor screws to 9 Nm (80 lb in). 5. Install the mirror glass. Refer to Outside Rearview Mirror Glass Replacement (See: Service and Repair/Outside Rearview Mirror Glass Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Door Component Views Power Mirror Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Door Component Views > Page 10285 Power Mirror Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10286 Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DE6) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10296 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10302 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10312 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10313 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10314 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10315 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution > Page 10318 Paint: Service Precautions Clearcoat/Ultraviolet Screeners Caution Clearcoat/Ultraviolet Screeners Caution Caution: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Basecoat/Clearcoat Paint Systems Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of the GM Approved Refinish Materials book to identify the paint systems you may use that have been engineered to meet GM standards. The GM Approved Refinish Materials book supplies all approved products, including volatile organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed procedures for materials used in their paint system. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Basecoat/Clearcoat Paint Systems > Page 10321 Paint: Application and ID Paint Identification Paint Identification Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Note: Always refer to the GM Approved Refinish Materials book. This book identifies the paint systems you may use. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Under the Passenger Seat Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 10326 1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger (KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1) 7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 10327 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Sunroof / Moonroof Motor: Locations Passenger Compartment/Roof Component Views Front of the Headliner Components (CF5) 1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 10333 Sunroof / Moonroof Motor: Diagrams Component Connector End Views Sunroof Motor (CF5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 10334 Sunroof / Moonroof Motor: Service and Repair Power Sunroof Motor Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Front of the Headliner Components (CF5) 1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 10338 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 10339 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures Sunroof / Moonroof Track: Procedures Sunroof Track Timing/Synchronization Important: An improperly timed window panel can affect sunroof functionality, water test results, and windnoise. If a repair involves the removal of sunroof motor for any reason, it is recommended that the window timing be reset. 1. To reset window timing, the motor must be removed. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). 2. Open the sunroof window to the fully vented position. 3. Apply even pressure to the front of the window to move it to the fully open position. 4. There is a hard stop at the rear of the full open position, which will stop the left and right cables in an identical rearward position. 5. Once fully open and timed, the motor may be reinstalled. 6. The motor is not timed to the position of the window, as the motor will continuously run in either direction until the switch is deactivated. Once the motor is reinstalled, test sunroof for functionality. The left and right sides of the window should move, and close, simultaneously. Both rear corners of the window should appear to be the same height, in the relation to the upper frame when in the closed position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10344 Sunroof / Moonroof Track: Removal and Replacement Sunroof Guide Replacement Sunroof Guide Replacement Removal Procedure 1. Open the sunshade to the full open position. 2. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair). 3. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). Note: Note the location of the bolts, size and color when removing, for proper installation. 4. Remove the screws from around the lower frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10345 Note: Place the sunroof module on a flat protective cover, face down. 5. Remove the sunroof module and window from the vehicle. 6. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). 7. Remove the cam plate screws (1). 8. Remove the cam plate (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10346 9. Lift upward on the drive cables (2) to release the cam (3) from the upper frame. 10. Remove the left and right side drive cable tube covers (1) from the drive cable (2). Two drive cable tube covers to each side. 11. Push the drive cables up into the upper frame, this will allow the window to open manually. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10347 Note: Place the sunroof module on a flat protective cover, face down. 12. The sunroof window must be in the full open position to do the following: 1. Unhook the wind deflector slide blocks (1) from each side. 2. Unhook the wind deflector tabs (2) from the center of the upper frame. 3. Remove the wind deflector. Note: Mark the left and right sides of the guides in respect to the frame. This will assist in the alignment of the window to the module later. Note the location of the bolts, size and color when removing, for proper installation. 13. Remove the two screws (1) on each side of the guides (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10348 Note: Place the sunroof module on a flat protective cover, face down. It is necessary to slide the guides about 1 cm (1 3/8 in) rearward to release the upper frame. 14. Rotate the upper frame back and fourth. Pushing forward on the upper frame until it is over the guides. 15. Remove the upper frame (2) from the window and guides (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10349 16. Remove the guides (1) from the drive cables (4) and slides (3). Installation Procedure 1. Install the guides (1) to the drive cables (4) and slides (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10350 2. Install the upper frame (2) to the window and guides (1). Note: Place the sunroof module on a flat protective cover, face down. Rotate the upper frame back and fourth until it is over the guides. Refer to the marked positions on the guides in respect to the frame. 3. Place the guides about 1 cm (1 3/8 in) rearward to reinstall the upper frame. 4. Pull rearward on the upper frame until the screws holes align with the guide holes. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10351 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Using the marks on the left and right sides of the guides to reinstall the window to the module for alignment. 5. Install the two screws (1) to each side of the guides (2). Install the bolts, size and color to the proper location. Tighten the screw to 3 Nm (27 lb in). Note: Place the sunroof module on a flat protective cover, face down. 6. The sunroof window must be in the full open position to do the following: 1. Install the wind deflector. 2. Hook the wind deflector slide blocks (1) to each side. 3. Hook the wind deflector tabs (2) to the center of the upper frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10352 7. Install the left and right side drive cable tube covers (1) to the cable (2). Two drive cable tube covers to each side. 8. Pull the drive cables down through the guides and around the upper frame, this will allow the window to be closed manually. 9. Install the drive cables (2) with cam (3). Ensure that the chamfered edge of the gear is directed upward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10353 10. Install the cam plate (2). 11. Install the cam plate screws (1). Tighten the screw to 3 Nm (27 lb in). 12. Install the sunroof module to the vehicle. 13. Install the lower frame to the sunroof module. 14. Tighten the lower frame to the sunroof module screws. Tighten the screw to 3 Nm (27 lb in). 15. Install the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). 16. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair). 17. Verify the operations of the sunroof window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10354 Sunroof Sliding Block Guide Replacement Sunroof Sliding Block Guide Replacement Removal Procedure 1. Open the sunshade to the full open position. 2. Remove the sunroof module upper frame. Refer to Sunroof Frame Replacement - Upper (See: Sunroof / Moonroof Frame/Service and Repair/Sunroof Frame Replacement - Upper). 3. Remove the guides (1) from the sliders (2). 4. Remove the drive cables and sliders (1) from the guides. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10355 5. Remove the lever (1) by rotating it forward and slide it together with the locker slider forward. 6. Remove the lever carefully by using a flat-bladed tool between the track and the levers. The track is not serviceable. If damaged replace the sunroof window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10356 7. Remove the front end of the locker slider to the outside and slide it forward. 8. Apply a light coat of lubricant (1) to the following parts: * The guides * The curve of the driving slider * The lever * The locker sliders * The track is not serviceable. If damaged replace the sunroof window. It bonded to the sunroof window panel. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10357 1. Place the locker slide, with the front to the outside, and slide it rearward. 2. Slide the locker slider forward. 3. Push the pin (1) of the lever (2) carefully through the track (3) in the locker slide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10358 4. Slide the lever together with the locker slide rearward, and rotate the lever rearward. 5. Mount the driving slide (1) to the lever and the front tumbler. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10359 Important: Do Not force the guides to the sliders. Use care. 6. Position the front tumbler and the driving slide in-line with each other. 7. Slide the guide carefully over the front tumbler and driving slider extends 4.5 cm (2 in) out of the guide. 8. Mount the drive cable on the driving slide. 9. Rotate the drive cable, so that the points of the oval cable end fit into the guides. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Procedures > Page 10360 10. Slide the guides rearwards until the end of the driving slide is 1 cm (3/8 in) within the guide. 11. Install the sunroof module upper frame. Refer to Sunroof Frame Replacement - Upper (See: Sunroof / Moonroof Frame/Service and Repair/Sunroof Frame Replacement - Upper). 12. Verify the operation of the sunroof. 13. Close the sunshade. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement Removal Procedure 1. Open the sunshade to the full open position. 2. Open the sunroof window to the full open position. 1. Unhook the wind deflector slide blocks (1) from each side. 2. Unhook the wind deflector tabs (2) from the rear of the upper frame. 3. Remove the wind deflector. Installation Procedure 1. The window Must be in the full open position to do the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Page 10364 1. Install the wind deflector to the upper frame. 2. Hook the wind deflector slide blocks (1) to each side. 3. Hook the wind deflector tabs (2) into the rear of the upper frame. 4. Verify operation of the wind deflector. 2. Verify operations of the sunroof window. 3. Close the sunroof. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Frame: Customer Interest Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10373 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10374 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10375 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10376 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10377 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10383 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10384 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10385 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10386 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10387 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement - Upper Sunroof Frame Replacement - Upper Removal Procedure 1. Open the sunshade to the full open position. 2. Open the sunroof window to the full open position. 3. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair). 4. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). Note: Note the location of the bolts, size and color when removing, for proper installation. 5. Remove the screws from around the lower frame. Refer to Sunroof Frame Replacement - Lower (See: Sunroof Frame Replacement - Lower). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10390 Note: Place the sunroof module on a flat protective cover, face down. 6. Remove the sunroof module and window from the vehicle. 7. Remove the cam plate screws (1). 8. Remove the cam plate (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10391 9. Lift upward on the drive cables (2) to release the cam (3) from the upper frame. 10. Remove the left and right side drive cable tube covers (1), two on each side. 11. Push the drive cables up into the upper frame, this will allow the window to open manually. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10392 Note: Place the sunroof module on a flat protective cover, face down. 12. The sunroof window must be in the full open position to do the following: 1. Unhook the wind deflector slide blocks (1) from each side. 2. Unhook the wind deflector tabs (2) from the center of the upper frame. 3. Remove the wind deflector. Note: Mark the left and right sides of the guides in respect to the frame. This will assist in the alignment of the window to the module later. Note the location of the bolts, size and color when removing, for proper installation. 13. Remove the two screws (1) on each side of the guides (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10393 Note: Place the sunroof module on a flat protective cover, face down. It is necessary to slide the guides about 1 cm (1 3/8 in) rearward to release the upper frame. 14. Rotate the upper frame back and fourth. Pushing forward on the upper frame until it is over the guides. 15. Remove the upper frame (2) from the window and guides (1). Do not remove the drive cables or sliders from the guides. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10394 1. Install the upper frame (2) to the window and guides (1). Note: Place the sunroof module on a flat protective cover, face down. Rotate the upper frame back and fourth until it is over the guides. Refer to the marked positions on the guides in respect to the frame. 2. Place the guides about 1 cm (1 3/8 in) rearward to reinstall the upper frame. 3. Pull rearward on the upper frame until the screws holes align with the guide holes. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10395 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Using the marks on the left and right sides of the guides to reinstall the window to the module for alignment. 4. Install the two screws (1) to each side of the guides (2). Install the bolts, size and color to the proper location. Tighten the screw to 3 Nm (27 lb in). Note: Place the sunroof module on a flat protective cover, face down. 5. The window must be in the full open position to do the following: 1. Install the wind deflector. 2. Hook the wind deflector slide blocks (1) to each side. 3. Hook the wind deflector tabs (2) to the center of the upper frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10396 6. Install the left and right side drive cable tube covers (1), two drive cable tube covers to each side Note: Ensure that the chamfered edge of the gear is directed upward. 7. Install the drive cables (2) with cam (3) to the sunroof module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10397 8. Install the cam plate (2). 9. Install the cam plate screws (1). Tighten the cam plate screw to 3 Nm (27 lb in). 10. Manually close the sunroof window to the sunroof module assembly on the bench. 11. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10398 12. Clean the old sealer (1) from the opening of the roof outside roof panel area around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner P/N 08984 or equivalent to clean the roof panel. 13. Apply synthetic lubrication with Teflon GM P/N 12371287 (Canadian P/N 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. Note: You may want to use some disposable gloves to keep the adhesive from getting onto your hand. 14. A caulk gun applicator will be needed to apply the adhesive. 15. Apply a 2 mm (1 1/16 in) bead of CRL7711 or 3M(TM) P/N 08506 Clear or P/N 08509 Black sealant around the entire edge of the upper frame assembly and dry seal. 16. Install the sunroof module assembly into the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10399 17. Install the lower sunroof frame to the sunroof module. 18. Install the screws into the proper locations of the lower sunroof frame assembly. 19. Tighten the screws in the lower sunroof frame using a cross-tightening sequence. Tighten the screws to 3 Nm (27 lb in). 20. Place the sunroof window to the full open position. This will allow the window, motor and cables to be timed. Refer to Sunroof Track Timing/Synchronization (See: Sunroof / Moonroof Track/Service and Repair/Procedures). 21. Install the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). 22. Close the sunroof window fully. 23. Verify proper operation of the sunroof. 24. Clean any excessive adhesive off the roof panel with a plastic-type scraper/razor blade and a 3M(TM) General Purpose Cleaner P/N 08984 or equivalent. 25. Perform a water test to verify the leak has been fixed. 26. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10400 Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement - Lower Sunroof Frame Replacement - Lower Removal Procedure 1. Open the sunshade to the full open position. 2. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair). 3. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). Note: Note the location of the bolts, size and color when removing, for proper installation. 4. Remove the screws from around the lower frame. 5. Remove the lower frame from sunroof module. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Sunroof Frame Replacement - Upper > Page 10401 1. Install the lower frame to the sunroof module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the screws to the lower frame of the sunroof module. Install the bolts, size and color to the proper location. Tighten the screw to 3 Nm (27 lb in). 3. Push the sunroof window to the full open position. This will allow the window, motor and cables to be timed. 4. Install the sunroof motor. Refer to Power Sunroof Motor Replacement (See: Sunroof / Moonroof Motor/Service and Repair). 5. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair). 6. Verify operations of the sunroof window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Gear Assembly > Component Information > Service and Repair Sunroof / Moonroof Gear Assembly: Service and Repair Sunroof Cam Assembly Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Front Trim Cover Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Panel: Customer Interest Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10416 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10417 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10418 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10419 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10420 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Panel: All Technical Service Bulletins Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10426 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10427 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10428 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10429 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10430 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Page 10431 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement Removal Procedure 1. Remove the sunroof module guides. Refer to Sunroof Guide Replacement (See: Sunroof / Moonroof Track/Service and Repair/Removal and Replacement/Sunroof Guide Replacement). Important: Place the sunroof module on a protective cover, face down. 2. Remove the sunroof module sliders. Refer to Sunroof Sliding Block Guide Replacement (See: Sunroof / Moonroof Track/Service and Repair/Removal and Replacement/Sunroof Sliding Block Guide Replacement). Important: Mark the left and right sides of the guides in respect to the frame. This will assist in the alignment of the window to the module later. 3. Remove the guides (1) from the left and right. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Page 10432 4. Remove the drive cables (1) and sliders (2) from the guides. 5. Remove the locker slider (1). 1. Rotate the lever forward, slide the locker slider forward. 2. Carefully remove the lever, using a suitable tool by inserting it between the track and the lever. The track is not serviceable, if damaged replace the sunroof window. 6. Remove the sunroof window from the module. Installation Procedure 1. Install the sunroof window to the module. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Page 10433 2. Install the locker slider (1). 1. Rotate the lever forward, align the locker slider with the hole in the lever and slider forward. 2. Using a suitable tool, insert it between the track and the lever to lock it in place. The track is not serviceable, if damaged replace the sunroof window. 3. Install the drive cables (1) and sliders (2) to the guides. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Page 10434 Important: Using the marks on the left and right sides of the guides to reinstall the window to the module for alignment. 4. Install the sunroof module guides (1) to the left and right. 5. Install the sunroof module sliders. Refer to Sunroof Sliding Block Guide Replacement (See: Sunroof / Moonroof Track/Service and Repair/Removal and Replacement/Sunroof Sliding Block Guide Replacement). 6. Install the sunroof module guides. Refer to Sunroof Guide Replacement (See: Sunroof / Moonroof Track/Service and Repair/Removal and Replacement/Sunroof Guide Replacement). 7. Verify operations of the sunroof window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10443 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10444 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10445 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10446 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10447 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10453 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10454 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10455 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10456 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10457 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10458 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement Removal Procedure 1. Open the sunshade to the full open position. 2. Remove the sunroof window seal (1) from the upper frame (2). 1. Carefully remove the old seal. 2. Open the sunroof window completely when working along the front and sides. 3. Move the sunroof window into the maximum tilt position when working on the rear side. 3. Remove the sunroof window seal from the upper frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10459 4. Remove all traces of sealant from around the inside upper frame groove to prevent leaks. 5. Clean the upper frame as follows, clean around the inside surface and edges with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth. Installation Procedure 1. Install a adhesive sealant bead around the outside (1) of the groove of the upper frame 2 mm (1/16 in) thick. 2. Install a adhesive sealant bead only along the front (2), on the inside of the groove 2 mm (1/16 in) thick. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10460 Important: Put the seam of the sunroof window seal in the front under the window holder. This is done to prevent tension in the seal. 3. Place the new sunroof window seal in the frame without pressure. 4. Install the front center under the window holder and push the sunroof window seal from the sides to the rear only 1 mm (1/32 in) into the groove. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10461 5. Install the sunroof window seal entirely into the groove, the seal Must be kept flush fitted in the frame. 6. Remove excessive adhesive sealant from around the sunroof window seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10462 7. The sunroof must remain open until the adhesive sealant is dry. * Check the curing time on the adhesive sealant. * If the sunroof window has to be close after repair , it is advisable to apply a strip of masking tape in the front center over the seal before closing. This is done to prevent the seal from pulling out of the groove, * When the repairs are completed and cured, water test the vehicle to ensure no leaks. 8. Verify operations of the sunroof window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Front Seat Head Restraint Replacement Head Rest: Service and Repair Front Seat Head Restraint Replacement Front Seat Head Restraint Replacement Removal Procedure 1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to release the head restraint retainer, simultaneously lift up on the head restraint while applying inward pressure to the tool in the retainer release port (1). 4. Remove the head restraint from the seat assembly. Installation Procedure 1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head restraint retainer prevents the head restraint from being removed from the seat assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Front Seat Head Restraint Replacement > Page 10468 Head Rest: Service and Repair Front Seat Head Restraint Guide Replacement Front Seat Head Restraint Guide Replacement Removal Procedure 1. Remove the front seat assembly. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the front seat head restraint. Refer to Front Seat Head Restraint Replacement (See: Front Seat Head Restraint Replacement). 3. Pull the seat back cover and the seat back pad up high enough to expose the head restraint guides. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Seat Back/Service and Repair/Front Seat Back Cushion Cover and Cushion Pad Replacement). 4. Squeeze the retaining tabs located at the bottom of the guides together in order to remove the guides from the seat frame. 5. Remove the guides from the seat back frame. Installation Procedure 1. Install the guides to the seat back frame, verifying that the lower retainers are fully seated to the frame. 2. Install the guide with the locking tab (1) on the seat's right-hand side. 3. Install the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Seat Back/Service and Repair/Front Seat Back Cushion Cover and Cushion Pad Replacement). 4. Install the front seat head restraint. Refer to Front Seat Head Restraint Replacement (See: Front Seat Head Restraint Replacement). 5. Install the seat assembly. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Front Seat Head Restraint Replacement > Page 10469 Head Rest: Service and Repair Rear Seat Head Restraint Replacement Rear Seat Head Restraint Replacement Removal Procedure 1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to release the head restraint retainer, simultaneously lift up on the head restraint while applying inward pressure to the tool in the retainer release port (1). 4. Remove the head restraint from the seat assembly. Installation Procedure 1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head restraint retainer prevents the head restraint from being removed from the seat assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Passenger Seat Components - 2 of 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10477 1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2) Under the Passenger Seat Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10478 1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger (KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1) 7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10479 Power Seat Motor: Diagrams Component Connector End Views Seat Adjuster Motor Assembly - Driver (AG1) Seat Adjuster Motor Assembly - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10480 Seat Lumbar Motor - Driver (AR9) Seat Lumbar Motor - Passenger (AR9) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10481 Seat Vertical Motor - Driver (AG1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10482 Power Seat Motor: Service and Repair Power Seat Adjuster Mechanism Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 3. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 4. Remove the switch bezel. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10483 6. Remove the 2 push pins (1) securing the seat cushion spacer (2) to the seat adjuster. 7. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 8. Remove the seat back and recliner assemblies from the seat adjuster. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10484 9. Disconnect the harness (3) from the seat position sensor (1). 10. Remove the 2 nuts (2) securing the seat position switch (1) to the seat adjuster. 11. Remove the seat harness connectors (2) from the power seat adjuster (1). 12. Remove the seat harness from the seat adjuster assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10485 13. Disconnect the seat belt buckle electrical connector. 14. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 15. Remove the seat cushion cover and foam. 16. Remove the 4 nuts (1) securing the seat cushion frame to the seat adjusters. 17. Remove the power seat adjuster. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10486 1. Install the seat cushion spacer (2) to the seat adjuster with the 2 push pins (1). 2. Install the seat harness connectors (2) to the power seat adjuster (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10487 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the seat position switch (1) to the seat adjuster with 2 nuts (2). Tighten the seat position switch nuts to 24 Nm (18 lb ft). 4. Connect the wiring harness (3) to the seat position switch (1). 5. Install the power seat adjuster to the seat cushion frame with 4 nuts (1). Tighten the seat cushion frame mounting nuts to 24 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10488 6. Install the seat cushion foam pad and cover to the frame. 7. Install the seat belt buckle assembly (1) through the seat cushion pad. 8. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2). Tighten the seat belt buckle bolt to 55 Nm (41 lb ft). 9. Connect the seat belt buckle electrical connector (1). 10. Position the seat back assembly on the seat cushion assembly. 11. Install the 2 bolts (1) securing the seat back and recliner assemblies to the seat adjuster. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 10489 12. Install the front, rear, and side J-strips (1, 2) to the underside of the seat. 13. Install the switch bezel. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 14. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 15. Install the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 16. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Passenger Seat Components - 2 of 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 10493 1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 10494 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver X1 (AG1) Seat Adjuster Switch - Driver X2 (AG1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 10495 Seat Adjuster Switch - Passenger (AG2) Seat Lumbar Adjuster Switch - Driver (AG1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 10496 Seat Lumbar Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Removal Procedure 1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 3. Remove the buttons from the switch (2). 4. Release the tabs (1) that retain the seat switch (2) to the seat bezel. 5. Disconnect the power seat switch harness (1) from the seat harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 10499 6. Remove the power seat switch from the seat bezel. Installation Procedure 1. Connect the power seat switch harness (1) to the seat harness. 2. Install the power seat switch (2) to the seat bezel. Verify that the retaining tabs (1) are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 10500 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Removal Procedure 1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 3. Remove the buttons from the switch (3). 4. Release the tabs (4) that retain the seat switch (3) to the seat bezel. 5. Disconnect the lumbar switch harness (1) from the seat harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 10501 6. Remove the lumbar switch from the seat bezel. Installation Procedure 1. Connect the lumbar switch harness (1) to the seat harness. 2. Install the lumbar switch (3) to the seat bezel. Verify that the retaining tabs (4) are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement Seat Back: Service and Repair Front Seat Back Cushion Cover and Cushion Pad Replacement Front Seat Back Cushion Cover and Cushion Pad Replacement Removal Procedure 1. Adjust lumbar to a relaxed position. 2. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 3. Remove the seat back release handle. Refer to EZ Entry Seat Manual Release Knob Replacement (See: Service and Repair/EZ Entry Seat Manual Release Knob Replacement). 4. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 5. Remove the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Front Seat Head Restraint Replacement). 6. Release the J-strip (1) across the bottom of the seat back cover. 7. Compress the seat back pad in order to relieve the pressure against the seat cover. 8. Using a side to side motion, carefully lift off the seat back cover, partially separating the seat back cover from the foam pad. Important: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the pad. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10506 9. Release the lower Velcro retaining strips (2) located inside the seat cover (1). 10. Remove the hog rings that retain the seat back pad to the reinforcement bar located at the top of the seat back. 11. Spread the pad apart and push the cover and pad up over the seat back in order to expose the head restraint guides. 12. Remove the head restraint guides by squeezing the locking tabs together and pulling the restraint guides upward and out of the seat frame. 13. Remove the seat back cover the remainder of the way from the seat back. 14. Disconnect the electrical connector for the seat back heating element, located near the seat belt retractor, if equipped. 15. Carefully remove the seat back pad from the seat back frame. 16. Remove the seat back heater element. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See: Seat Heater/Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement). Installation Procedure 1. Install the seat back heater element. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See: Seat Heater/Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement). 2. Position the seat back pad to the seat back frame. 3. Connect the electrical connector to the seat back heating element, if equipped. 4. Partially install the seat back cover over the top of the seat. 5. Install the head restraint guides to the seat frame. Ensure that the locking tabs are fully seated. The guide with the release tab goes on the right-hand side. 6. Install the hog rings that retain the seat back pad to the reinforcement bar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10507 7. Pull the seat cover (1) over the seat back pad (3). 8. Press the seat cover hook and loop retaining strips (2) together by firmly running your hand over the seat back cover (1). 9. Install the J-strip (1) across the bottom of the seat back cover. 10. Install the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Front Seat Head Restraint Replacement). 11. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 12. Install the seat back release handle. Refer to EZ Entry Seat Manual Release Knob Replacement (See: Service and Repair/EZ Entry Seat Manual Release Knob Replacement). 13. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10508 Seat Back: Service and Repair Front Seat Back Frame Replacement Front Seat Back Frame Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 2. Remove the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Front Seat Back Cushion Cover and Cushion Pad Replacement). 3. Remove the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service and Repair/Front Seat Lumbar Support Replacement). 4. Remove the 4 seat recliner mounting bolts (1) securing the seat back frame to the seat back recliner mechanism. 5. Remove the seat back frame. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10509 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the seat back frame to the seat back recliner mechanism with 4 bolts (1). Tighten the front seat recliner bolts to 24 Nm (18 lb ft). 2. Install the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service and Repair/Front Seat Lumbar Support Replacement ). 3. Install the seat back pad and cover. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Front Seat Back Cushion Cover and Cushion Pad Replacement). 4. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10510 Seat Back: Service and Repair Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 3. Release the J-strip (1) on the bottom edge of the seat back cover. 4. Remove the seat cushion cover and pad from the seat frame. 5. Remove the hog rings securing the cover to the pad. Installation Procedure 1. Install the hog rings securing the cover to the pad. 2. Install the seat cushion cover and pad over the seat frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10511 3. Install the J-strip (1) on the cover. 4. Install the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 5. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10512 Seat Back: Service and Repair Rear Seat Back Cushion Frame Replacement (Crew Cab) Rear Seat Back Cushion Frame Replacement (Crew Cab) Removal Procedure 1. Remove the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 3. Remove the screw securing the side trim covers to the seat cushion frame. 4. Remove the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)). 5. Remove the head restraint guides from the seat back frame by pinching the tabs on the guides and pulling the guides out of the frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10513 6. Remove the seat back latch assembly. Refer to Rear Seat Back Latch Replacement (See: Seat Latch/Service and Repair). 7. Remove the bolt securing the seat back frame to the seat cushion frame. 8. Remove the seat back frame by pulling the frame off the seat cushion frame stud. 9. Inspect the white nylon bushing on the seat back frame for wear or damage and replace if necessary. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10514 1. Install the seat back frame by pushing the frame onto the seat cushion frame stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt securing the seat back frame to the seat cushion frame. Tighten the rear bench seat back frame mounting bolt to 50 Nm (37 lb ft). 3. Install the seat back latch assembly. Refer to Rear Seat Back Latch Replacement (See: Seat Latch/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10515 4. Install the head restraint guides in the seat back frame by pushing the guides through the frame until the tabs lock into place. 5. Install the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)). 6. Install the screw securing the side trim covers to the seat cushion frame. Tighten the rear bench seat side trim cover screw to 1.5 Nm (13 lb in). 7. Install the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 8. Install the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10516 Seat Back: Service and Repair Front Seat Back Cushion Cover and Cushion Pad Replacement Front Seat Back Cushion Cover and Cushion Pad Replacement Removal Procedure 1. Adjust lumbar to a relaxed position. 2. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 3. Remove the seat back release handle. Refer to EZ Entry Seat Manual Release Knob Replacement (See: Service and Repair/EZ Entry Seat Manual Release Knob Replacement). 4. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 5. Remove the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Front Seat Head Restraint Replacement). 6. Release the J-strip (1) across the bottom of the seat back cover. 7. Compress the seat back pad in order to relieve the pressure against the seat cover. 8. Using a side to side motion, carefully lift off the seat back cover, partially separating the seat back cover from the foam pad. Important: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the pad. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10517 9. Release the lower Velcro retaining strips (2) located inside the seat cover (1). 10. Remove the hog rings that retain the seat back pad to the reinforcement bar located at the top of the seat back. 11. Spread the pad apart and push the cover and pad up over the seat back in order to expose the head restraint guides. 12. Remove the head restraint guides by squeezing the locking tabs together and pulling the restraint guides upward and out of the seat frame. 13. Remove the seat back cover the remainder of the way from the seat back. 14. Disconnect the electrical connector for the seat back heating element, located near the seat belt retractor, if equipped. 15. Carefully remove the seat back pad from the seat back frame. 16. Remove the seat back heater element. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See: Seat Heater/Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement). Installation Procedure 1. Install the seat back heater element. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See: Seat Heater/Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement). 2. Position the seat back pad to the seat back frame. 3. Connect the electrical connector to the seat back heating element, if equipped. 4. Partially install the seat back cover over the top of the seat. 5. Install the head restraint guides to the seat frame. Ensure that the locking tabs are fully seated. The guide with the release tab goes on the right-hand side. 6. Install the hog rings that retain the seat back pad to the reinforcement bar. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10518 7. Pull the seat cover (1) over the seat back pad (3). 8. Press the seat cover hook and loop retaining strips (2) together by firmly running your hand over the seat back cover (1). 9. Install the J-strip (1) across the bottom of the seat back cover. 10. Install the head restraint. Refer to Front Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Front Seat Head Restraint Replacement). 11. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 12. Install the seat back release handle. Refer to EZ Entry Seat Manual Release Knob Replacement (See: Service and Repair/EZ Entry Seat Manual Release Knob Replacement). 13. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Front Seat Back Frame Replacement Front Seat Back Frame Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10519 Removal Procedure 1. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 2. Remove the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Front Seat Back Cushion Cover and Cushion Pad Replacement). 3. Remove the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service and Repair/Front Seat Lumbar Support Replacement). 4. Remove the 4 seat recliner mounting bolts (1) securing the seat back frame to the seat back recliner mechanism. 5. Remove the seat back frame. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10520 1. Install the seat back frame to the seat back recliner mechanism with 4 bolts (1). Tighten the front seat recliner bolts to 24 Nm (18 lb ft). 2. Install the lumbar assembly. Refer to Front Seat Lumbar Support Replacement (See: Service and Repair/Front Seat Lumbar Support Replacement ). 3. Install the seat back pad and cover. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Front Seat Back Cushion Cover and Cushion Pad Replacement). 4. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 3. Release the J-strip (1) on the bottom edge of the seat back cover. 4. Remove the seat cushion cover and pad from the seat frame. 5. Remove the hog rings securing the cover to the pad. Installation Procedure 1. Install the hog rings securing the cover to the pad. 2. Install the seat cushion cover and pad over the seat frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10521 3. Install the J-strip (1) on the cover. 4. Install the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 5. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). Rear Seat Back Cushion Frame Replacement (Crew Cab) Rear Seat Back Cushion Frame Replacement (Crew Cab) Removal Procedure 1. Remove the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 3. Remove the screw securing the side trim covers to the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10522 4. Remove the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)). 5. Remove the head restraint guides from the seat back frame by pinching the tabs on the guides and pulling the guides out of the frame. 6. Remove the seat back latch assembly. Refer to Rear Seat Back Latch Replacement (See: Seat Latch/Service and Repair). 7. Remove the bolt securing the seat back frame to the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10523 8. Remove the seat back frame by pulling the frame off the seat cushion frame stud. 9. Inspect the white nylon bushing on the seat back frame for wear or damage and replace if necessary. Installation Procedure 1. Install the seat back frame by pushing the frame onto the seat cushion frame stud. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10524 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt securing the seat back frame to the seat cushion frame. Tighten the rear bench seat back frame mounting bolt to 50 Nm (37 lb ft). 3. Install the seat back latch assembly. Refer to Rear Seat Back Latch Replacement (See: Seat Latch/Service and Repair). 4. Install the head restraint guides in the seat back frame by pushing the guides through the frame until the tabs lock into place. 5. Install the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10525 6. Install the screw securing the side trim covers to the seat cushion frame. Tighten the rear bench seat side trim cover screw to 1.5 Nm (13 lb in). 7. Install the rear head rest restraints, if equipped. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). 8. Install the seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). Rear Seat Back Cushion Frame Replacement (Extended Cab) Rear Seat Back Cushion Frame Replacement (Extended Cab) Removal Procedure 1. Remove the rear seat back from the vehicle by grasping the back and lifting straight up. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10526 2. Remove the hog rings (1) from the cover (2). 3. Remove the seat back cover from the seat back frame/pad. Installation Procedure 1. Install the seat back cover over the seat back frame/pad. 2. Install the hog rings (1) on the cover (2). 3. Install the rear seat back in the vehicle by aligning the hooks in the slots and pushing the seat back downward. Driver or Passenger Seat Back Cushion Finish Panel Replacement Driver or Passenger Seat Back Cushion Finish Panel Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 2. Remove the front seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Front Seat Back Cushion Cover and Cushion Pad Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10527 3. Remove the 2 hog ring fasteners (3) on the bottom of the seat back panel (2). 4. Remove the push-pin fastener (1) from the top of the seat back panel. 5. Remove the seat-back panel. Installation Procedure 1. Position the seat back panel on the seat-back frame. 2. Install the seat back panel to the frame with a push-pin fastener (1) at the top of the panel. 3. Install the 2 hog ring fasteners (3) to the bottom of the seat back panel (2). 4. Install the front seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Front Seat Back Cushion Cover and Cushion Pad Replacement). 5. Install the seat in the vehicle. Refer to Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement) or Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Rear Seat Back Cushion Replacement (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10528 Rear Seat Back Cushion Replacement (Crew Cab) Removal Procedure 1. Release the rear seat back latches. 2. Remove the screw securing the side trim covers to the seat cushion frame. 3. Remove the bolt securing the seat back frame to the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10529 4. Remove the seat back frame by pulling the frame off the seat cushion frame stud. 5. Inspect the white nylon bushing on the seat back frame for wear or damage and replace if necessary. Installation Procedure 1. Install the seat back frame by pushing the frame onto the seat cushion frame stud. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10530 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolt securing the seat back frame to the seat cushion frame. Tighten the seat back frame mounting bolt to 50 Nm (37 lb ft). 3. Install the screw securing the side trim covers to the seat cushion frame. Rear Seat Back Cushion Replacement (Extended Cab) Rear Seat Back Cushion Replacement (Extended Cab) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Back Cushion Cover and Cushion Pad Replacement > Page 10531 1. Remove the rear seat back from the vehicle by grasping the back and lifting straight up. 2. Remove the rear seat back from the vehicle. Installation Procedure 1. Position the rear seat back by aligning the hooks with the slots in the vehicle. 2. Install the rear seat back by pushing the seat back downward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10536 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10537 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10538 Seat Cover: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10539 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10540 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10541 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10542 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10543 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10544 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement Seat Cushion: Service and Repair Front Seat Cushion Frame Replacement Front Seat Cushion Frame Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10549 5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 9. Remove the screws (2) that retain the lumbar adjustment mechanism (1) to the seat adjuster. 10. Remove the lumbar cable from the lumbar adjustment mechanism. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10550 11. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 12. Remove the seat back assembly from the seat cushion assembly. 13. Disconnect the seat belt buckle electrical connector (1). 14. Remove any clips or straps securing the electrical harness to the bottom of the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10551 15. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 16. Remove the seat cushion cover and foam. 17. Remove the assist spring. 18. Disconnect the wire harness for the lumbar and seat heat switches and pull the harness (2) back through the hole in the seat cushion frame. 19. Remove the 4 nuts (1) securing the seat cushion frame to the seat adjuster. 20. Remove the seat cushion frame. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10552 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the seat cushion frame to the seat adjuster with 4 nuts (1). Tighten the front seat cushion frame mounting nuts to 24 Nm (18 lb ft). 2. Route the wire harness for the lumbar and seat heat switches through the hole in the seat cushion frame and connect the connectors. 3. Install the assist spring. 4. Install the seat cushion foam pad and cover to the frame. 5. Install the seat belt buckle assembly (1) through the seat cushion pad. 6. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2). Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10553 7. Connect the seat belt buckle electrical connector (1). 8. Install any clips or straps securing the electrical harness to the bottom of the seat cushion frame. 9. Position the seat back assembly on the seat cushion assembly. 10. Install the 2 bolts (1) securing the seat recliner to the seat adjuster. Tighten the front seat recliner bolts to 24 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10554 11. Install the lumbar adjustment mechanism (1) to the seat adjuster with the 2 screws (2). 12. Install the lumbar cable to the lumbar adjustment mechanism. 13. Install the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 14. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 15. Install the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 16. Install the front, rear, and side J-strips (1, 2) to the underside of the seat. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10555 17. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in). 18. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 19. Install the cupholder to the seat by pushing it straight onto the bracket. 20. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10556 Seat Cushion: Service and Repair Front Seat Cushion Cover and Pad Replacement Front Seat Cushion Cover and Pad Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10557 5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 9. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 10. Remove the seat back assembly from the seat cushion assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10558 11. Disconnect the seat belt buckle electrical connector (1). 12. Remove any clips or straps securing the electrical harness to the bottom of the seat cushion frame. 13. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 14. Remove the seat cushion cover and foam. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10559 15. Remove the hog rings (3) securing the cover (1) to the pad (2). 16. If the pad is being replaced, peel the heating element (3) off of the pad (2), if equipped. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10560 1. If the pad is being replaced, stick the adhesive-backed heating element (3) onto the pad (2), if equipped. 2. Install the cover (1) to the pad (2) with the hog rings (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10561 3. Install the seat cushion foam pad and cover to the frame. 4. Install the seat belt buckle assembly (1) through the seat cushion pad. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2). Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft). 6. Connect the seat belt buckle electrical connector (1). 7. Install any clips or straps securing the electrical harness to the bottom of the seat cushion frame. 8. Position the seat back assembly on the seat cushion assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10562 9. Install the 2 bolts (1) securing the seat recliner to the seat adjuster. Tighten the front seat recliner bolts to 24 Nm (18 lb ft). 10. Install the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 11. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 12. Install the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 13. Install the front, rear, and side J-strips (1, 2) to the underside of the seat. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10563 14. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in). 15. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 16. Install the cupholder to the seat by pushing it straight onto the bracket. 17. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10564 Seat Cushion: Service and Repair Rear Seat Cushion Cover and Pad Replacement (Crew Cab) Rear Seat Cushion Cover and Pad Replacement (Crew Cab) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the seat belt buckles (1) from the seat cover loops (2). 3. Release the J-strips (1) on the cover. 4. Remove the seat cushion cover and pad from the seat frame (2). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10565 1. Install the seat cushion cover and pad over the seat frame (2). 2. Install the J-strips (1) on the cover. 3. Install the seat belt buckles (1) through the seat cover loops (2). 4. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10566 Seat Cushion: Service and Repair Rear Seat Cushion Cover and Pad Replacement (Extended Cab) Rear Seat Cushion Cover and Pad Replacement (Extended Cab) Removal Procedure 1. Remove the rear folding seat cushion from the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Service and Repair/Folding Seat Replacement (Extended Cab)). 2. Release the J-strips (2) on the cover (1). 3. Remove the seat cushion cover from the seat frame/pad. Installation Procedure 1. Install the seat cushion cover over the seat frame/pad. 2. Install the J-strips (2) on the cover (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10567 3. Install the rear folding seat cushion in the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Service and Repair/Folding Seat Replacement (Extended Cab)). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10568 Seat Cushion: Service and Repair Front Seat Cushion Frame Replacement Front Seat Cushion Frame Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10569 5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 9. Remove the screws (2) that retain the lumbar adjustment mechanism (1) to the seat adjuster. 10. Remove the lumbar cable from the lumbar adjustment mechanism. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10570 11. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 12. Remove the seat back assembly from the seat cushion assembly. 13. Disconnect the seat belt buckle electrical connector (1). 14. Remove any clips or straps securing the electrical harness to the bottom of the seat cushion frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10571 15. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 16. Remove the seat cushion cover and foam. 17. Remove the assist spring. 18. Disconnect the wire harness for the lumbar and seat heat switches and pull the harness (2) back through the hole in the seat cushion frame. 19. Remove the 4 nuts (1) securing the seat cushion frame to the seat adjuster. 20. Remove the seat cushion frame. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10572 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the seat cushion frame to the seat adjuster with 4 nuts (1). Tighten the front seat cushion frame mounting nuts to 24 Nm (18 lb ft). 2. Route the wire harness for the lumbar and seat heat switches through the hole in the seat cushion frame and connect the connectors. 3. Install the assist spring. 4. Install the seat cushion foam pad and cover to the frame. 5. Install the seat belt buckle assembly (1) through the seat cushion pad. 6. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2). Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10573 7. Connect the seat belt buckle electrical connector (1). 8. Install any clips or straps securing the electrical harness to the bottom of the seat cushion frame. 9. Position the seat back assembly on the seat cushion assembly. 10. Install the 2 bolts (1) securing the seat recliner to the seat adjuster. Tighten the front seat recliner bolts to 24 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10574 11. Install the lumbar adjustment mechanism (1) to the seat adjuster with the 2 screws (2). 12. Install the lumbar cable to the lumbar adjustment mechanism. 13. Install the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 14. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 15. Install the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 16. Install the front, rear, and side J-strips (1, 2) to the underside of the seat. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10575 17. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in). 18. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 19. Install the cupholder to the seat by pushing it straight onto the bracket. 20. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Front Seat Cushion Cover and Pad Replacement Front Seat Cushion Cover and Pad Replacement Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10576 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the cupholder from the seat by pulling it straight off the bracket. 3. Remove the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 4. Remove the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10577 5. Unclip the front, rear, and side J-strips (1, 2) on the underside of the seat. 6. Remove the lumbar knob by pulling the knob straight away from the seat, if equipped. 7. Remove the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 8. Remove the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 9. Remove the 2 bolts (1) securing the seat recliner to the seat adjuster. 10. Remove the seat back assembly from the seat cushion assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10578 11. Disconnect the seat belt buckle electrical connector (1). 12. Remove any clips or straps securing the electrical harness to the bottom of the seat cushion frame. 13. Remove the bolt (2) securing the seat belt buckle assembly (1) to the seat adjuster. 14. Remove the seat cushion cover and foam. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10579 15. Remove the hog rings (3) securing the cover (1) to the pad (2). 16. If the pad is being replaced, peel the heating element (3) off of the pad (2), if equipped. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10580 1. If the pad is being replaced, stick the adhesive-backed heating element (3) onto the pad (2), if equipped. 2. Install the cover (1) to the pad (2) with the hog rings (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10581 3. Install the seat cushion foam pad and cover to the frame. 4. Install the seat belt buckle assembly (1) through the seat cushion pad. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the seat belt buckle assembly (1) to the seat adjuster with the bolt (2). Tighten the front seat belt buckle bolt to 55 Nm (41 lb ft). 6. Connect the seat belt buckle electrical connector (1). 7. Install any clips or straps securing the electrical harness to the bottom of the seat cushion frame. 8. Position the seat back assembly on the seat cushion assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10582 9. Install the 2 bolts (1) securing the seat recliner to the seat adjuster. Tighten the front seat recliner bolts to 24 Nm (18 lb ft). 10. Install the seat switch bezel, if equipped. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 11. Install the lumbar knob by pushing the knob straight onto the shaft, if equipped. 12. Install the recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 13. Install the front, rear, and side J-strips (1, 2) to the underside of the seat. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10583 14. Install the 3 bolts (1) securing the cupholder bracket to the seat frame , if equipped. Tighten the front seat cupholder bracket bolts to 9.1 Nm (80 lb in). 15. Install the front seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion Outer Trim Panel Replacement). 16. Install the cupholder to the seat by pushing it straight onto the bracket. 17. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Rear Seat Cushion Cover and Pad Replacement (Crew Cab) Rear Seat Cushion Cover and Pad Replacement (Crew Cab) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10584 1. Remove the rear bench seat from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the seat belt buckles (1) from the seat cover loops (2). 3. Release the J-strips (1) on the cover. 4. Remove the seat cushion cover and pad from the seat frame (2). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10585 1. Install the seat cushion cover and pad over the seat frame (2). 2. Install the J-strips (1) on the cover. 3. Install the seat belt buckles (1) through the seat cover loops (2). 4. Install the rear bench seat in the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). Rear Seat Cushion Cover and Pad Replacement (Extended Cab) Rear Seat Cushion Cover and Pad Replacement (Extended Cab) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10586 1. Remove the rear folding seat cushion from the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Service and Repair/Folding Seat Replacement (Extended Cab)). 2. Release the J-strips (2) on the cover (1). 3. Remove the seat cushion cover from the seat frame/pad. Installation Procedure 1. Install the seat cushion cover over the seat frame/pad. 2. Install the J-strips (2) on the cover (1). 3. Install the rear folding seat cushion in the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Service and Repair/Folding Seat Replacement (Extended Cab)). Rear Seat Cushion Frame Replacement (Crew Cab) Rear Seat Cushion Frame Replacement (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10587 Removal Procedure 1. Remove the rear bench seat cushion from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the rear cupholder. Refer to Rear Seat Cup Holder Replacement (Crew Cab) (See: Service and Repair/Rear Seat Cup Holder Replacement (Crew Cab)). 3. Remove the rear seat back assembly. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 4. Remove the rear seat cushion cover and pad. Refer to Rear Seat Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Cushion Cover and Pad Replacement (Crew Cab))Rear Seat Cushion Cover and Pad Replacement (Extended Cab) (See: Rear Seat Cushion Cover and Pad Replacement (Extended Cab)). 5. Remove the rear seat cushion frame. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10588 1. Install the rear seat cushion cover and pad to the frame. Refer to Rear Seat Cushion Cover and Pad Replacement (Crew Cab) (See: Rear Seat Cushion Cover and Pad Replacement (Crew Cab))Rear Seat Cushion Cover and Pad Replacement (Extended Cab) (See: Rear Seat Cushion Cover and Pad Replacement (Extended Cab)). 2. Install the rear seat back assembly. Refer to Rear Seat Back Cushion Replacement (Extended Cab) (See: Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Extended Cab))Rear Seat Back Cushion Replacement (Crew Cab) (See: Seat Back/Service and Repair/Rear Seat Back Cushion Replacement (Crew Cab)). 3. Install the rear cupholder. Refer to Rear Seat Cup Holder Replacement (Crew Cab) (See: Service and Repair/Rear Seat Cup Holder Replacement (Crew Cab)). 4. Install the rear bench seat cushion in the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement ). Rear Seat Cushion Frame Replacement (Extended Cab) Rear Seat Cushion Frame Replacement (Extended Cab) Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10589 1. Remove the rear folding seat cushion from the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Service and Repair/Folding Seat Replacement (Extended Cab)). 2. Release the J-strips (2) on the cover (1). 3. Remove the seat cushion cover from the seat frame/pad. Installation Procedure 1. Install the seat cushion cover over the seat frame/pad. 2. Install the J-strips (2) on the cover (1). 3. Install the rear folding seat cushion in the vehicle. Refer to Folding Seat Replacement (Extended Cab) (See: Service and Repair/Folding Seat Replacement (Extended Cab)). Seat Cushion Outer Trim Panel Replacement Seat Cushion Outer Trim Panel Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10590 Removal Procedure 1. Remove the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). 2. Remove the 3 screws retaining the trim panel to the seat. 3. Remove the front seat cushion outer trim panel from the vehicle. Installation Procedure 1. Align the front seat cushion outer trim panel to the seat assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 seat cushion outer trim panel mounting screws. Tighten the front seat cushion outer trim panel screws to 1.5 Nm (13 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Frame Replacement > Page 10591 3. Install the seat back recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Driver or Passenger Seat Recliner Handle Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10596 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10597 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10598 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10599 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10600 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10601 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10602 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10603 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10604 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10605 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10606 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10607 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10608 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10609 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10610 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10611 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10612 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10613 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10614 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10615 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10616 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10617 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10618 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10619 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10620 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10621 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10622 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10623 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10624 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10625 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10626 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10627 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10628 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10629 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10630 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10631 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10632 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10633 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10634 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10635 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10636 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10637 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10638 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10639 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10640 Seat Heater: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10641 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10642 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10643 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10644 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10645 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10646 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10647 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10648 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10649 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10650 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10651 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10652 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10653 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10654 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10655 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10656 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10657 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10658 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10659 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10660 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10661 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10662 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10663 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10664 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10665 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10666 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10667 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10668 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10669 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10670 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10671 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10672 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10673 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10674 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10675 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10676 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10677 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10678 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10679 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10680 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10681 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10682 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10683 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10684 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10685 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10686 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10687 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10688 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10689 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10690 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10691 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10692 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10693 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10694 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10695 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10696 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10697 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10698 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10699 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10704 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10705 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10715 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10716 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10717 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10718 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10719 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10720 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10721 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10722 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10723 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10724 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10725 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10726 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10727 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10728 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10729 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10730 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10731 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10732 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10733 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10734 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10735 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10736 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10737 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10738 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10739 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10740 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10741 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10742 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10743 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10744 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10745 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10746 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10747 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10748 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10749 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10750 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10751 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10752 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10753 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10754 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10755 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10756 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10757 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10758 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10759 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10760 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10761 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10762 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10763 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10764 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10765 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10766 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10767 Seat Heater: Connector Views Component Connector End Views Heated Seat Element - Driver Back (KA1) Heated Seat Element - Passenger Back (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10768 Seat Heater: Electrical Diagrams Heated/Cooled Seat Schematics Driver Seat Passenger Seat Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10769 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 10770 Seat Heater: Description and Operation Heated Seats Description and Operation Heated Seats System Operation The driver and front passenger seats are heated using electric heater elements located in the seat cushions and seat backs. The heated seat control module is connected to the seat cushion element and harness assembly, and controls the battery positive voltage used to supply the seat heater elements. The heated seat switch and a thermistor, located in the seat cushion, are inputs to the heated seat control module. Ignition voltage is supplied to the heated seat switch from the HVAC 20A fuse in the underhood BEC. When the heated seat switch is in the high or low positions, voltage is supplied through one of the internal resistors to the switch signal circuit. Once the seat cushion has reached the desired temperature the heated seat control module will maintain the thermistor signal circuit voltage level by switching the heater element supply circuit on or off as necessary. The passenger heated seat switch must be enabled through the seat belt switch in order for heated seat operation to occur. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Seat Heater: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Seats Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Seat Heating and Cooling (See: Symptom Related Diagnostic Procedures/Symptoms Seat Heating and Cooling) in order to identify the correct procedure for diagnosing the system and where the procedure is located. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10773 Seat Heater: Symptom Related Diagnostic Procedures Symptoms - Seat Heating and Cooling Symptoms - Seat Heating and Cooling Important: Review the system description in order to familiarize yourself with the system functions. Refer to Heated Seats Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the heated seat system. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics). Symptom List Refer to Heated Seat Inoperative (See: Heated Seat Inoperative) in order to diagnose the symptom. Heated Seat Inoperative Heated Seat Inoperative Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Battery voltage is supplied at all times to the heated seat module from the HTD/SEATS 20A fuse located in the underhood fuse block. Ignition voltage is supplied to the heated seat switch from the PWR HTR SWITCH 20A fuse also located in the underhood fuse block. When the heated seat switch is in either the HI or LO heat position, battery voltage is applied through the switch contacts, one of the internal resistors, and the switch signal circuit to the heated seat module. In response to this signal, the heated seat module applies battery voltage through the heater element control circuit to the seat cushion and seat back heater elements for heated seat operation. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated Seats Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Circuit/System Verification Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10774 Driver Heated Seat 1. Ignition ON, operate the heated seat switch to the high and low heat positions. The heated seat switch indicator should illuminate when the switch is in the high and low positions. ‹› If the heated seat switch indicator does not illuminate or is always illuminated, refer to the Driver Heated Seat Switch Circuit Test. 2. If the heated seat switch indicator operates normal, refer to the Heated Seat Circuit Test. Passenger Heated Seat 1. Ignition ON, seat belt buckled, operate the heated seat switch to the high and low heat positions. The heated seat switch indicator should illuminate when the switch is in the high and low positions. ‹› If the heated seat switch indicator does not illuminate or is always illuminated, refer to the Passenger Heated Seat Switch Circuit Test. 2. If the heated seat switch indicator operates normal, refer to the Heated Seat Circuit Test. Circuit/System Testing Driver Heated Seat Switch Circuit Test 1. Ignition OFF, disconnect the harness connector at the heated seat switch. 2. Test for less than 5 ohms between the ground circuit terminal E and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal C and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. 4. If all circuits test normal, test or replace the heated seat switch. Passenger Heated Seat Switch Circuit Test 1. Ignition OFF, disconnect the harness connector at the heated seat switch. 2. Test for less than 5 ohms between the ground circuit terminal E and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal C and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. 4. Connect a test lamp between the ignition circuit terminal C and the signal circuit terminal D. 5. Buckle and unbuckle the passenger seat belt. The test lamp should be OFF when buckled and ON when unbuckled. ‹› If the test lamp is always on, test the signal circuit for a short to ground. If the circuit tests normal, replace the seat belt buckle. ‹› If the test lamp is always OFF, test the signal circuit for an open/high resistance. If the circuit tests normal, replace the seat belt buckle. 6. If all circuits test normal, test or replace the heated seat switch. Heated Seat Circuit Test 1. Ignition OFF, disconnect the harness connector at the heated seat module. 2. Test for less than 5 ohms between the ground circuit terminal 4 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify that a test lamp illuminates between the B+ circuit terminal 5 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. Ignition OFF, test for 2.5K ohms between the signal circuit terminal 6 and ground with the heated seat switch in the HIGH heat position. ‹› If less than the specified value, test the signal circuit for a short to ground. If the signal circuit tests normal, test or replace the heated seat switch. ‹› If greater than the specified value, test the signal circuit for an open/high resistance. If the signal circuit tests normal, test or replace the heated seat switch. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10775 5. Test for 4.9K ohms between the signal circuit terminal C and ground with the heated seat switch in the LOW heat position. ‹› If not the specified value, test or replace the heated seat switch. 6. Test for 2K-15K ohms between the signal circuit terminal 2 and the ground circuit terminal 4. ‹› If not within the specified range, replace the seat cushion heater element. 7. Disconnect the harness connector at the seat back heater element. 8. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 9. At the seat back heater element, test for 1-10 ohms between terminal A and terminal B. ‹› If not within the specified range, replace the seat back heater element. 10. Test for 1-10 ohms between the heated seat module connector terminal 7 and the seat back heater element connector terminal B. ‹› If not within the specified range, replace the seat cushion heater element. 11. If all circuits test normal, replace the heated seat module. Component Test Heated Seat Switch 1. Ignition OFF, disconnect the harness connector at the heated seat switch. 2. Test for infinite resistance between the terminals listed below with the switch in the open position. * Signal terminal B and ignition terminal C * Ignition terminal C and ground terminal A ‹› If not the specified value, replace the heated seat switch. 3. Test for 2.5K ohms between the signal terminal B and the ignition terminal C with the switch in the HIGH heat position. ‹› If not the specified value, replace the heated seat switch. 4. Test for 4.9K ohms between the signal terminal B and the ignition terminal C with the switch in the LOW heat position. ‹› If not the specified value, replace the heated seat switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Driver or Passenger Seat Back Cushion Heater Replacement (See: Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement) * Driver or Passenger Seat Cushion Heater Replacement (See: Service and Repair/Driver or Passenger Seat Cushion Heater Replacement) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement Seat Heater: Service and Repair Driver or Passenger Seat Back Cushion Heater Replacement Driver or Passenger Seat Back Cushion Heater Replacement Removal Procedure 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). 2. Remove the seat back cover to expose the heater element. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Seat Back/Service and Repair/Front Seat Back Cushion Cover and Cushion Pad Replacement). 3. Disconnect the electrical harness from the heater element. 4. Remove the heater element (1) by peeling the element off the pad (2). 5. Pull the heater element electrical harness through the hole (3) in the pad. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 10778 1. Install the heater element electrical harness through the hole (3) in the pad. 2. Install the adhesive-backed heater element (1) to the pad (2) by pressing in place. 3. Connect the electrical harness to the heater element. 4. Install the seat back cover. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement (See: Seat Back/Service and Repair/Front Seat Back Cushion Cover and Cushion Pad Replacement). 5. Install the seat in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement - Bucket). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 10779 Seat Heater: Service and Repair Driver or Passenger Seat Cushion Heater Replacement Driver or Passenger Seat Cushion Heater Replacement Removal Procedure 1. Remove the front seat assembly from the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). 2. Remove the front seat cushion cover and pad. Refer to Front Seat Cushion Cover and Pad Replacement (See: Seat Cushion/Service and Repair/Front Seat Cushion Cover and Pad Replacement). 3. Disconnect the electrical harness from the heater element. 4. Remove the heater element (1) by peeling the element off the pad (2). 5. Pull the heater element electrical harness through the hole (3) in the pad. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 10780 1. Install the heater element electrical harness through the hole (3) in the pad. 2. Install the adhesive-backed heater element (1) to the pad (2) by pressing in place. 3. Connect the electrical harness to the heater element. 4. Install the front seat cushion cover and pad. Refer to Front Seat Cushion Cover and Pad Replacement (See: Seat Cushion/Service and Repair/Front Seat Cushion Cover and Pad Replacement). 5. Install the front seat assembly in the vehicle. Refer to Front Seat Replacement - Bucket (See: Service and Repair/Front Seat Replacement Bucket) or Split Bench Seat Replacement (See: Service and Repair/Split Bench Seat Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Under the Passenger Seat Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 10784 1 - Seat Adjuster Motor Assembly - Passenger (AG2) 2 - Inflatable Restraint Seat Position Sensor (SPS) - Passenger 3 - Seat Belt Buckle - Passenger 4 - Heated Seat Control Module - Passenger (KA1) 5 - Seat Lumbar Motor - Passenger (AG2) 6 - Heated Seat Element - Passenger Back (KA1) 7 - Seat Adjuster Motor Assembly - Passenger Connector (AG2) 8 - X313 9 - X315 (AG2) 10 X318 (KA1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 10785 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair Rear Seat Back Latch Replacement Removal Procedure 1. Remove the rear bench seat cushion from the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement). 2. Remove the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) (See: Seat Back/Service and Repair/Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)). 3. Remove the 2 screws (2) securing the latch release strap bracket (1) to the seat back frame. 4. Remove the 4 screws (2) securing the latch assembly (1) to the seat back frame. 5. Remove the seat back latch from the seat back frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 10789 Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Remove the seat back latch (1) to the seat back frame with the 4 screws (2). Tighten the rear bench seat back latch mounting screws to 12 Nm (9 lb ft). 2. Install the 2 screws (2) securing the latch release strap bracket (1) to the seat back frame. Tighten the rear bench seat back latch release strap bracket screws to 1.5 Nm (13 lb in). 3. Install the screw securing the side trim covers to the seat cushion frame. Tighten the rear bench seat side trim cover screw to 1.5 Nm (13 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 10790 4. Install the seat back cover and pad. Refer to Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab) (See: Seat Back/Service and Repair/Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab)). 5. Install the rear bench seat cushion in the vehicle. Refer to Rear Bench Seat Replacement (See: Service and Repair/Rear Bench Seat Replacement ). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck Seat Track: Customer Interest Interior - Front Manual Seat(s) Won't Adjust, Stuck TECHNICAL Bulletin No.: 10-08-50-006 Date: June 02, 2010 Subject: Front Manual Seat(s) Won't Adjust Forward or Rearward, Sticks or Binds (Install Revised Seat Adjuster Bar, Replace Seat Adjuster) Models: 2004-2010 Chevrolet Colorado 2004-2010 GMC Canyon with Seat RPO AM6 or AR9 Condition Some customers may comment that the front seat(s) appear to be stuck in position and they are unable to move the seat forward or rearward in the vehicle. Cause This condition may be caused by the seat adjuster bar (handle) bending or coming out of position. This may also cause damage to the plastic adjuster blocks located in the seat adjuster assembly. Seat tracks (adjuster assemblies) that are not parallel to each other may contribute to the development of this condition. Correction Use the following procedure to repair the affected seat(s). 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement in SI. 2. Locate the adjuster bar (handle). Determine if the handle pin(s) have come out of the plastic adjuster block(s). 3. If the pin is in the block, inspect the gap between the adjuster bar and the plastic adjuster blocks. There should be no space between the two components. 4. If the pin(s) are out of the block(s) or there is a gap, the adjuster bar needs to be replaced with the revised part listed below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 10799 5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front. 7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any damage where the adjuster bar engages into the holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement in SI for replacement procedures. 8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends of the bar, it may bend at the pivot mount holes. Ensure that the curved portion of the bar is in the upward position. 9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard adjuster blocks. Ensure that there is no gap between the two components. 10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement in SI. 11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat adjuster function. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 10800 Warranty Information For vehicles repaired under warranty, use: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck Seat Track: All Technical Service Bulletins Interior - Front Manual Seat(s) Won't Adjust, Stuck TECHNICAL Bulletin No.: 10-08-50-006 Date: June 02, 2010 Subject: Front Manual Seat(s) Won't Adjust Forward or Rearward, Sticks or Binds (Install Revised Seat Adjuster Bar, Replace Seat Adjuster) Models: 2004-2010 Chevrolet Colorado 2004-2010 GMC Canyon with Seat RPO AM6 or AR9 Condition Some customers may comment that the front seat(s) appear to be stuck in position and they are unable to move the seat forward or rearward in the vehicle. Cause This condition may be caused by the seat adjuster bar (handle) bending or coming out of position. This may also cause damage to the plastic adjuster blocks located in the seat adjuster assembly. Seat tracks (adjuster assemblies) that are not parallel to each other may contribute to the development of this condition. Correction Use the following procedure to repair the affected seat(s). 1. Remove the seat from the vehicle. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement in SI. 2. Locate the adjuster bar (handle). Determine if the handle pin(s) have come out of the plastic adjuster block(s). 3. If the pin is in the block, inspect the gap between the adjuster bar and the plastic adjuster blocks. There should be no space between the two components. 4. If the pin(s) are out of the block(s) or there is a gap, the adjuster bar needs to be replaced with the revised part listed below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 10806 5. Locate and remove the two fasteners that retain the adjuster bar to the inner and outer seat adjuster assemblies. 6. Remove the adjuster bar. Note that the bar is curved upward at the front. 7. With the adjuster bar removed, inspect the inboard and outboard plastic adjuster blocks for any damage where the adjuster bar engages into the holes in the adjuster blocks. If any damage is detected, the affected seat adjuster assembly must be replaced. The seat adjuster assemblies are available individually (inboard and outboard). Only replace the component that is damaged. Refer to Manual Seat Adjuster Mechanism Replacement in SI for replacement procedures. 8. Install the revised adjuster bar. When installing the bar, do not apply pressure to the outer ends of the bar, it may bend at the pivot mount holes. Ensure that the curved portion of the bar is in the upward position. 9. With the bar installed, inspect the area where the adjuster bar engages the inboard and outboard adjuster blocks. Ensure that there is no gap between the two components. 10. Reinstall the seat. Refer to Front Seat Replacement - Bucket or Split Bench Seat Replacement in SI. 11. Before tightening the seat mounting bolts, ensure that the inboard and outboard seat tracks are parallel and spaced 305 mm (12 in) apart as shown. 12. With the seat installed, verify the seat adjuster function. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 10-08-50-006 > Jun > 10 > Interior - Front Manual Seat(s) Won't Adjust, Stuck > Page 10807 Warranty Information For vehicles repaired under warranty, use: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views Power Door Lock Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10813 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10814 Power Door Lock Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10815 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Right Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10816 1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door Harness) Left Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Component Views > Page 10817 1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10818 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock/Window Switch - Driver X1 (A31/AU3) Door Lock/Window Switch - Driver X2 (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10819 Door Lock/Window Switch - Passenger (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10820 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door Door Lock Switch Replacement - Driver Door Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel opening. 4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate. 7. If replacing only the switch plate, retain the switches for transfer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10823 Installation Procedure 1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the switches (2, 5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the switch plate assembly to the door trim panel with the 2 screws. Tighten the front door switch plate screws to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Driver Door > Page 10824 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front Door Lock Switch Replacement - Passenger Front Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Door Component Views Power Mirror Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Door Component Views > Page 10829 Power Mirror Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10830 Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DE6) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Passenger Compartment/Roof Component Views Under the Driver Seat Components 1 - Seat Adjuster Motor Assembly - Driver (AG1) 2 - Seat Adjuster Switch - Driver X1 (AG1) 3 Seat Adjuster Switch - Driver X2 (AG1) 4 - Seat Adjuster Motor Assembly - Driver Connector (AG1) 5 - Seat Lumbar Motor - Driver (AG1) 6 - X307 (AG1) 7 - X314 8 - Heated Seat Element - Driver Back (KA1) 9 - X319 (KA1) 10 - Seat Vertical Motor - Driver 11 - Heated Seat Control Module Driver (KA1) 12 - Seat Belt Buckle - Driver 13 - Inflatable Restraint Seat Position Sensor (SPS) Driver Passenger Seat Components - 2 of 2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 10834 1 - Heated Seat Element - Passenger Cushion (KA1) 2 - Inflatable Restraint Passenger Presence System (PPS) Module 3 - Seat Lumbar Motor - Passenger (AG2) 4 - Heated Seat Element Passenger Back (KA1) 5 - X315 (AG2) 6 - Seat Adjuster Motor Assembly - Passenger (AG2) 7 Seat Belt Buckle - Passenger 8 - Seat Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 10835 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver X1 (AG1) Seat Adjuster Switch - Driver X2 (AG1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 10836 Seat Adjuster Switch - Passenger (AG2) Seat Lumbar Adjuster Switch - Driver (AG1) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 10837 Seat Lumbar Adjuster Switch - Passenger (AG2) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Removal Procedure 1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 3. Remove the buttons from the switch (2). 4. Release the tabs (1) that retain the seat switch (2) to the seat bezel. 5. Disconnect the power seat switch harness (1) from the seat harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 10840 6. Remove the power seat switch from the seat bezel. Installation Procedure 1. Connect the power seat switch harness (1) to the seat harness. 2. Install the power seat switch (2) to the seat bezel. Verify that the retaining tabs (1) are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 10841 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Removal Procedure 1. Remove the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). 2. Remove the switch bezel from the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 3. Remove the buttons from the switch (3). 4. Release the tabs (4) that retain the seat switch (3) to the seat bezel. 5. Disconnect the lumbar switch harness (1) from the seat harness. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch Replacement > Page 10842 6. Remove the lumbar switch from the seat bezel. Installation Procedure 1. Connect the lumbar switch harness (1) to the seat harness. 2. Install the lumbar switch (3) to the seat bezel. Verify that the retaining tabs (4) are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Refer to Driver or Passenger Seat Adjuster Switch Bezel Replacement (See: Seats/Service and Repair/Driver or Passenger Seat Adjuster Switch Bezel Replacement). 5. Install the seat cushion outer trim panel. Refer to Seat Cushion Outer Trim Panel Replacement (See: Seats/Seat Cushion/Service and Repair/Seat Cushion Outer Trim Panel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Front of the Headliner Components (CF5) 1 - Sunroof Switch X2 2 - Sunroof Opening 3 - G300 4 - Sunroof Motor 5 - Sunroof Switch 6 Sunroof Switch X1 7 - Sunroof Ground Lead Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 10846 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 10847 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Lower Hinge Replacement - Body Side Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Body Side Endgate Lower Hinge Replacement - Body Side Removal Procedure 1. Remove the endgate from the vehicle. Refer to Endgate Replacement (See: Service and Repair). 2. Remove the bolts retaining the endgate hinge to the body. 3. Remove the endgate hinge from the body. Installation Procedure 1. Install the endgate hinge to the body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Lower Hinge Replacement - Body Side > Page 10853 2. Install the bolts retaining the endgate hinge to the body and tighten to 20 Nm (15 lb ft). 3. Install the endgate to the vehicle. Refer to Endgate Replacement (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Lower Hinge Replacement - Body Side > Page 10854 Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Endgate Side Endgate Lower Hinge Replacement - Endgate Side Removal Procedure 1. Remove the endgate from the vehicle. Refer to Endgate Replacement (See: Service and Repair). 2. Remove the bolts retaining the endgate hinge to the endgate. 3. Remove the endgate hinge from the endgate. Installation Procedure 1. Install the endgate hinge to the endgate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Lower Hinge Replacement - Body Side > Page 10855 2. Install the bolts retaining the endgate hinge to the endgate and tighten to 20 Nm (15 lb ft). 3. Install the endgate to the vehicle. Refer to Endgate Replacement (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Endgate Latch and Cable Assembly Replacement Tailgate Latch: Service and Repair Endgate Latch and Cable Assembly Replacement Endgate Latch and Cable Assembly Replacement Removal Procedure 1. Open and support the endgate. 2. Remove the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). 3. Disconnect the clips (1) retaining the latch rods (2) to the handle. 4. Remove the latch rods (2) from the retaining clips (1). 5. Remove the support cable (1) from the endgate striker bolt by sliding the cable forward and off the striker bolt head. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Endgate Latch and Cable Assembly Replacement > Page 10860 6. Remove the bolts retaining the latch/support cable assembly to the endgate. 7. Remove the latch assembly from the endgate. Installation Procedure 1. Install the latch/support cable assembly to the endgate, ensuring the latch rod is oriented correct to the endgate handle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the latch assembly to the endgate. Tighten the latch/support cable assembly bolts to 25 Nm (18 lb ft). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Endgate Latch and Cable Assembly Replacement > Page 10861 3. Install the support cable (1) onto the bolt head of the endgate striker bolt. 4. Install the latch rods (2) into the retaining clips (1). 5. Connect the clips (1) retaining the latch rods (2) to the endgate handle. 6. Install the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). 7. Close the endgate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Endgate Latch and Cable Assembly Replacement > Page 10862 Tailgate Latch: Service and Repair Pickup Box Endgate Striker Replacement Pickup Box Endgate Striker Replacement Removal Procedure 1. Open and support the endgate. 2. Remove the support cable (1) from the endgate striker bolt by sliding the cable forward and off the striker bolt head. 3. Remove the bolts retaining the endgate striker to the body. 4. Remove the endgate striker from the body. Installation Procedure 1. Install the endgate striker to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Endgate Latch and Cable Assembly Replacement > Page 10863 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the endgate striker to the body. Tighten the endgate striker bolts to 25 Nm (18 lb ft). 3. Install the support cable (1) onto the head of the striker bolt, sliding the cable rearward until the bolt head is retaining in the keyhole slot. 4. Remove the endgate support and close the endgate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair Endgate Handle Replacement Removal Procedure 1. Remove the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). 2. Disconnect the clips (1) retaining the endgate latch rods (2) to the endgate handle. 3. Remove the endgate latch rods (2) from the retaining clips (1). 4. Remove the bolts retaining the endgate handle to the endgate. 5. Remove the endgate handle from the endgate. 6. Remove the lock cylinder from the endgate handle if equipped. Refer to Endgate Lock Cylinder Replacement (See: Locks/Door Locks/Door Lock Cylinder/Service and Repair). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Page 10867 1. Install the lock cylinder to the endgate handle if equipped. Refer to Endgate Lock Cylinder Replacement (See: Locks/Door Locks/Door Lock Cylinder/Service and Repair). 2. Install the endgate handle to the endgate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts retaining the endgate handle to the endgate. Tighten the endgate handle bolts to 9 Nm (80 lb in). 4. Install the endgate latch rods (2) to the retaining clips (1) on the endgate handle. 5. Connect the clips (1) retaining the endgate latch rods (2) to the handle. 6. Install the endgate cover. Refer to Pickup Box Endgate Latch Cover Replacement (). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and Repair Tie Down Hook / Bracket: Service and Repair Pickup Box Tie Down Loop Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service Precautions/Approved Equipment for Collision Repair Warning). 1. Locate and drill out the spot welds. 2. Remove the tie down loop. Installation Procedure 1. Prepare all mating surfaces as necessary. 2. Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair (). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and Repair > Page 10871 3. Position the tie down loop. 4. Plug weld accordingly. 5. Clean and prepare all welded surfaces. 6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 7. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems (See: Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement Removal Procedure 1. Remove the front bumper. Refer to Front Bumper Replacement (See: Bumper/Front Bumper/Service and Repair). 2. Remove the right tow hook nuts and bolts from the frame rail. 3. Remove the right tow hook from the vehicle. 4. Remove the left tow hook nuts and bolts from the frame rail. 5. Remove the left tow hook from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Page 10875 1. Install the left tow hook to the frame rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nuts and the bolts to the frame rail and tighten the bolts to 100 Nm (74 lb ft). 3. Install the left tow hook to the frame rail. 4. Install the nuts and the bolts to the frame rail and tighten the bolts to 100 Nm (74 lb ft). 5. Install the front bumper. Refer to Front Bumper Replacement (See: Bumper/Front Bumper/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair Truck Bed Cover: Service and Repair Pickup Box Liner Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 2. Remove the air inlet grill panel push-pin retainers. 3. Disconnect the washer hose. 4. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Position the air inlet grille panel to the vehicle. 2. Connect the washer hose. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 10885 3. Install the push-pin retainers. 4. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Auxiliary Weatherstrip Replacement Auxiliary Weatherstrip Replacement Crew cab shown, others similar. Removal Procedure 1. Open the front and rear door, as necessary. 2. Remove the auxiliary weatherstrip by pulling the weatherstrip (1) from the roof pinchweld flange (2). Installation Procedure 1. Install the auxiliary weatherstrip to the roof pinchweld flange by pressing the weatherstrip (1) onto the roof flange (2), until it is fully seated. 2. Close the front and rear door, as necessary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10891 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended) Front Door Opening Weatherstrip Replacement (Extended) Removal Procedure 1. Open the front and rear door. 2. Remove the front door opening weatherstrip (1) from the opening pinchweld flange. 3. Remove the front door opening weatherstrip from the vehicle. Installation Procedure 1. Align the paint dot on the front door weatherstrip to the notch (2) in the upper rear corner of the pitchweld flange. 2. Starting at the notch (2) in the upper rear corner, press the front door opening weatherstrip (1) onto the pinchweld flange until it is fully seated. 3. Pull the cord (3) on the front door opening weatherstrip, ensuring the weatherstrip lip overlaps the interior trim panels and headliner. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10892 4. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10893 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular, Crew) Front Door Opening Weatherstrip Replacement (Regular, Crew) Removal Procedure 1. Open the front door. 2. Remove the lower center pillar panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the front door opening weatherstrip (2) from the door opening pinchweld flange (1). 4. Remove the front door opening weatherstrip from the vehicle. Installation Procedure 1. Position the front door opening weatherstrip to the pinchweld flange. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10894 2. Starting at the upper rear corner, press the front door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Pull the cord (3) on the front door opening weatherstrip ensuring the weatherstrip lip overlaps the interior trim panels and headliner. 5. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10895 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement (Extended) Front Side Door Weatherstrip Replacement (Extended) Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the front door. 2. Remove the upper weatherstrip mold from the door by removing the integral weatherstrip pushpin (2) from the door using J 38778 , or equivalent. 3. Remove the lower weatherstrip mold from the door removing the integral weatherstrip pushpin (3) from the door using J 38778 , or equivalent. 4. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent, under the weatherstrip (1), and releasing the integral retainers from the door frame. 5. Remove the weatherstrip from the door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10896 1. Position the weatherstrip to the front door. 2. Install the upper weatherstrip mold to the door using the integral weatherstrip pushpin (2). 3. Install the lower weatherstrip mold to the door using the integral weatherstrip pushpin (3). 4. Install the weatherstrip around the front door frame using the integral retainers. 5. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10897 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement (Regular, Crew) Front Side Door Weatherstrip Replacement (Regular, Crew) Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the front door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent , under the weatherstrip (1) and releasing the integral retainers from the door frame. 3. Remove the weatherstrip from the front door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Auxiliary Weatherstrip Replacement > Page 10898 1. Position the weatherstrip to the front door. 2. Install the weatherstrip around the front door frame using the integral retainers. 3. Close the front door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Removal Procedure 1. Open the hood. 2. Remove the front hood seal by pulling downward on the seal, starting from one end. Installation Procedure 1. Open the hood. 2. Install the front hood seal by pressing the retainers into the hood openings. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 10903 3. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 10904 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Removal Procedure 1. Open the hood. 2. Grasp the rear hood seal at each retainer and lift upwards to remove. 3. Remove the seal from the upper cowl panel. Installation Procedure 1. Position the seal to the upper cowl panel. 2. Insert each retainer into the holes in the body. 3. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Removal Procedure 1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4. Remove the rear door opening weatherstrip from the vehicle. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10909 2. Starting at the upper rear corner, press the rear door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the interior trim panels and headliner. 5. Close the rear door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10910 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Rear Door Weatherstrip Replacement Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent, under the weatherstrip and releasing the integral retainers (2) from the door frame. 3. Remove the weatherstrip from the rear door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10911 1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame using the integral retainers (2). 3. Close the rear door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10912 Rear Door Weatherstrip: Service and Repair Rear Side Access Door Auxiliary Weatherstrip Replacement Rear Side Access Door Auxiliary Weatherstrip Replacement Removal Procedure 1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by pulling the weatherstrip from the rear door pinchweld flange. Installation Procedure 1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the weatherstrip into place until it is fully seated. 2. Close the front and side doors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10913 Rear Door Weatherstrip: Service and Repair Rear Side Door Wedge Replacement - Body Side Rear Side Door Wedge Replacement - Body Side Removal Procedure 1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint. 3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic, flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and painters (VMP) naptha. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10914 1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C (70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6. Remove the tape from the area around the wedge. 7. Close the rear side access door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10915 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Removal Procedure 1. Open the rear door. 2. Remove the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 3. Remove the rear door opening weatherstrip (2) from the door opening pinchweld flange (1). 4. Remove the rear door opening weatherstrip from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10916 1. Position the rear door opening weatherstrip to the pinchweld flange. 2. Starting at the upper rear corner, press the rear door opening weatherstrip (2) onto the pinchweld flange (1) until it is fully seated. 3. Install the lower center pillar trim panel. Refer to Center Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair). 4. Pull the cord (3) on the rear door opening weatherstrip ensuring the weatherstrip lip overlaps the interior trim panels and headliner. 5. Close the rear door. Rear Door Weatherstrip Replacement Rear Door Weatherstrip Replacement Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Removal Procedure 1. Open the rear door. 2. Remove the weatherstrip from around the door by inserting J 38778 , or equivalent, under the weatherstrip and releasing the integral retainers (2) from the door frame. 3. Remove the weatherstrip from the rear door. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10917 1. Position the weatherstrip to the rear door. 2. Install the weatherstrip around the rear door frame using the integral retainers (2). 3. Close the rear door. Rear Side Access Door Auxiliary Weatherstrip Replacement Rear Side Access Door Auxiliary Weatherstrip Replacement Removal Procedure 1. Open the front and side access doors. 2. Remove the rear door outer auxiliary weatherstrip by pulling the weatherstrip from the rear door pinchweld flange. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10918 1. Install the rear door auxiliary weatherstrip to the rear door pinchweld flange, by pressing the weatherstrip into place until it is fully seated. 2. Close the front and side doors. Rear Side Door Wedge Replacement - Body Side Rear Side Door Wedge Replacement - Body Side Removal Procedure 1. Open the rear side access door. 2. Apply tape to the area around the wedge to protect the paint. 3. Heat the wedge (1) using a heat gun 152 mm (6 in) from the surface. 4. Apply the heat using a circular motion for about 30 seconds. 5. Remove the wedge from the body using a plastic, flat-bladed tool. 6. Remove all adhesive from the body using 3M Scotch Brite molding adhesive remover disk 3M P/N 07201, or equivalent. 7. Clean the body surface using varnish makers and painters (VMP) naptha. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10919 Installation Procedure 1. Warm the body surface with a heat gun 152 mm (6 in) from the surface to a minimum of 21°C (70°F). 2. Remove the backing from the wedge (1). 3. Align the tabs on the wedge to the holes in the body. 4. Press the wedge to the body surface. 5. Inspect the wedge for proper adhesion. 6. Remove the tape from the area around the wedge. 7. Close the rear side access door. Rear Side Door Wedge Replacement - Door Side Rear Side Door Wedge Replacement - Door Side Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10920 1. Open the rear side access door. 2. Remove the wedge from the side access door by squeezing the retainer clip on the wedge and rotating the wedge downward. Installation Procedure 1. Install the wedge to the side access door by inserting the tabs into the slots on the door and rotating the wedge up until the retaining clip is fully seated. 2. Close the rear side access door. Weatherstrip Replacement Rear Side Access Door Weatherstrip Replacement Rear Side Access Door Tools Required J 38778 Door Trim Pad Clip Remover or Equivalent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10921 Removal Procedure 1. Open the front and rear side access doors. 2. Remove the upper molded detail from the front of the side access door, by inserting J 38778 under the weatherstrip mold and releasing the integral retaining pins (3) on the mold to the door. 3. Remove the lower molded detail from the front of the side access door, by inserting J 38778 under the weatherstrip mold and releasing the integral retaining pins (1) on the mold to the door. 4. Remove the weatherstrip from around the door, by inserting J 38778 under the weatherstrip on releasing the integral pins from the door. 5. Remove the weatherstrip from the side access door. Installation Procedure 1. Position the weatherstrip to the rear side access door. 2. Install the upper molded detail to the front of the rear side access door using the integral retaining pins (1). 3. Install the lower molded detail to the front of the rear side access door using the integral retaining pins (1). 4. Install the weatherstrip around the rear door frame using the integral retainers. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 10922 5. Close the front and rear side access doors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10931 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10932 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10933 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10934 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10935 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Water leaks/ Wind Noise From The Sunroof TECHNICAL Bulletin No.: 07-08-67-001B Date: June 22, 2009 Subject: Sunroof Leaks Water, Wind or Whistle Noise from Sunroof (Determine Source of Leak and Apply Sealer) Models: 2005-2009 Chevrolet Colorado 2005-2009 GMC Canyon with RPO CF5 Sunroof Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin 07-08-67-001A (Section 08 - Body & Accessories). Condition Some customers may comment on water entering into the vehicle from the sunroof area. Other customers may comment on a wind noise or whistle noise heard from the sunroof area when driving at different speeds. Design The sunroof module is designed to be completely sealed at the roof panel to help prevent water from traveling past the glass panel seal. The sunroof glass assembly does not have any glass panel adjustments. The sunroof assembly does not contain a water management drain tube system. When operating the sunroof, the glass panel moves rearward and slides up above the roof panel. Therefore, the vehicle must be driven or the exterior dried off sufficiently to remove excessive water prior to opening the sunroof glass. If the water is not sufficiently dissipated, some water may enter inside the vehicle. Cause Some earlier built vehicles with the sunroof option did not have any adhesive sealer installed on the upper sunroof frame assembly. Wind or Whistle Noise Test Procedure Determine the source of the wind or whistle noise. Refer to Air/Wind Noise in SI. Water Hose Test Procedure Perform a water hose test to determine where the leak is entering the sunroof assembly. Important Use a water hose without the nozzle attached at a controlled medium volume water flow. 1. Visually inspect the sunroof glass. The glass should be flush to the sunroof frame. If the glass (1) like in the graphic above is not flush, make sure no parts are broken or missing from the sunroof module assembly. 2. Make sure all seals and tracks are clean and free of debris. Use a dampened lint free cloth with warm water to clean the seals. Use GM(TM) Glass Cleaner, P/N 89021822 (in Canada, 992727) to clean the tracks. 3. Open the sunshade to the full open position. 4. Open the sunroof window to the full open position. 5. Remove the four outer trim cover screws located outside of the sunroof module. 6. Remove the outer trim cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10941 7. Remove the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 8. Have an assistant inside the vehicle to signal you when the leak is detected. 9. Perform a water test to verify the leak concern. 10. If a leak is found, try to pinpoint the exact location that the water is entering. It could be any of the following four areas: 1. The leak may be entering from the roof panel and upper sunroof frame. 2. The leak may be entering from the upper sunroof frame seal and lower frame. 3. The leak may be entering from the sunroof glass and glass seal. 4. The water may be entering from around the sunroof glass clip holder. 11. Dry off the sunroof glass, outer sunroof frame and the roof panel. 12. Tape off around the entire outside perimeter of the upper sunroof frame assembly and outside the roof panel with masking tape. 13. Start water testing at the left front outer roof panel and sunroof frame by removing one inch of tape at a time until the source of the leak can be pinpointed. 14. Proceed with the water test while removing the masking tape along the right front outer sunroof frame and roof panel until the complete area has been tested. 15. Tape off the entire area around the outside perimeter of the sunroof glass and sunroof frame with masking tape. 16. Proceed to water test up to the sunroof glass and sunroof frame. 17. Start water testing while removing the masking tape from the left front corner of the sunroof glass; then proceed along to the right front corner of the glass until the complete area has been tested. 18. Have an assistant signal you when the leak is detected. 19. Note the area you are water testing and mark the entry point of the water. 20. The leak could be from more than one area, so determine which conditions apply and follow the recommended corrections below. Condition 1 The leak condition is present between the roof panel (1) and the dry seal on the upper sunroof frame. Cause 1 The dry foam seal on the upper sunroof frame assembly may have collapsed or has become distorted, causing the leak. Correction 1 Remove the sunroof module assembly and apply CRL7711 Sealer (a one-part butyl adhesive) to the outer edge of the upper sunroof frame using the procedure listed below: 1. Remove the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. Important Note the size, color and locations of the lower sunroof frame screws when removing them. 2. Remove the six (black) TORX(R) screws from each side of the lower sunroof frame. Important Do Not remove the (red) TORX(R) screws from the track. 3. Remove the eight (gold) TORX(R) screws from the lower sunroof frame. 4. Remove the lower frame from the sunroof module assembly. Important Have a clean workbench with a flat protective cover. The cover will help protect the sunroof glass when the glass is placed face down on the bench. 5. Remove the sunroof module and window from the vehicle and place the glass side down on a clean bench. Tip The sunroof window can now be manually moved forward or backward. 6. Manually close the sunroof window to the sunroof module assembly. 7. Clean the outside area of the upper sunroof frame with GM(TM) Glass Cleaner for vehicles built without adhesive under the sunroof frame. If the sunroof frame has adhesive applied to the frame, use masking tape to clean the frame and seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10942 8. Clean the outside roof panel area (1) around the sunroof opening with GM(TM) Glass Cleaner if no adhesive has been used. If adhesive has been used, it may be necessary to use masking tape and a 3M(TM) General Purpose Adhesive Cleaner, P/N 08984, or equivalent, to clean the roof panel. 9. Apply GM Super Lube(R) with PTFE, P/N 12371287 (in Canada, 10953437) to the outside bare edges of the roof panel opening for the sunroof module. This grease is recommended for use on any bare edges around the sunroof opening. An acid brush can be used to apply the grease. 10. A caulk gun applicator will be needed to apply the adhesive (1). Tip You may want to use some disposable gloves to keep the adhesive from getting onto your hands. 11. Apply a 2 mm (1/16 in) bead (1) of CRL7711 Sealant around the entire edge of the upper frame assembly and dry seal. 12. Install the sunroof module assembly back into the vehicle. 13. Install the lower sunroof frame to the sunroof module. 14. Install the screws into the lower sunroof frame assembly. 15. Tighten the screws in the lower sunroof frame using the cross-tightening sequence. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Manually push the sunroof window to the full open position. This will allow the window, motors and cables to be timed. 17. Install the sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 18. Verify the proper operation of the sunroof. 19. Clean off any excessive adhesive (1) from the roof panel with a plastic-type scraper/razor blade while using a 3M(TM) General Purpose Cleaner, P/N 08984, or equivalent, as shown in the graphic above. 20. Perform a water test to verify the leak has been fixed. 21. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. Important A clicking sound can be heard when the retaining clips snap onto the upper frame. Open the sunroof and visually inspect from the roof area that the retaining clips on the front trim cover are installed properly. 22. Install the outer trim cover and four screws. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10943 Tighten Tighten the screws to 1 Nm (9 lb in). Condition 2 A leak condition between the lower sunroof frame (2) and the upper sunroof frame (3) at the window weather seal (4). Cause 2 The seal on the upper sunroof frame assembly may not have enough sealant under the seal. Correction 2 Apply GM(TM) Weatherstrip Adhesive, P/N 12345097 (in Canada, 10953479) to the weatherstrip sealing flange located in the upper sunroof frame. Condition 3 A leak from the sunroof window glass and sunroof window seal. Cause 3 The sunroof window seal may be deformed or compressed, not allowing the sunroof window glass to seal properly. Correction 3 Replace the sunroof window seal following the steps below: 1. Open the sunshade to the full open position. 2. Remove the old sunroof window seal (1) from the frame (2). Refer to Sunroof Window Seal Replacement in SI. 3. Install the new seal. Refer to Sunroof Window Seal Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10944 Condition 4 A leak from around the sunroof glass holder clip, known as a "blow out clip" (1). Cause 4 A lack of adhesive sealant under the sunroof window holder clip. Correction 4 Remove the sunroof window holder clip and apply a small amount of CRL7711 Sealant in the upper frame clip using the steps below. 1. Remove the power sunroof motor. Refer to Power Sunroof Motor Replacement in SI. 2. Remove the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 3. Remove the two screws from the sunroof gear plate. 4. Remove the gear plate. 5. Remove the gear. 6. Remove the two screws for the sunroof glass holder clip. 7. Apply a 2 mm (1/16 in) bead of CRL7711 Sealant to the upper sunroof frame clip area. 8. Install the glass holder clip. 9. Tighten the two screws. Tighten Tighten the two screws to 1 Nm (9 lb in). Important The chamfered edge of the gear goes toward the motor when reinstalling the gear. 10. Install the gear. 11. Install the gear plate and two screws. 12. Tighten the two screws. Tighten Tighten the screw to 2 Nm (18 lb in). 13. Install the lower sunroof frame. Refer to Sunroof Frame Replacement-Lower in SI. 14. Install the sunroof motor assembly. 15. Install the sunroof motor screws and tighten. Tighten Tighten the screws to 3 Nm (27 lb in). 16. Perform a water test to verify that the leak has been fixed. 17. Install the sunroof front trim cover. Refer to Sunroof Front Trim Cover Replacement in SI. 18. Install the outer trim cover and four screws. Tighten Tighten the screws to 1 Nm (9 lb in). Waterleak Odor in Vehicle Important For elimination of vehicle waterleak odor, refer to Bulletin Number 00-00-89-027D Eliminating Unwanted Odors in Vehicles. Dry out any wet components. Refer to Floor Carpet Drying in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-67-001B > Jun > 09 > Body - Water leaks/ Wind Noise From The Sunroof > Page 10945 Parts Information To order *CRL7711, contact the distributor CR Laurence Company Toll Free at 1-(800) 421-6144 from U.S. or Canada or access on the web at crlaurence.com to set up a customer account to place orders. The dealer also has the option to complete a referral request form to purchase the product through a local supplier. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10946 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement Removal Procedure 1. Open the sunshade to the full open position. 2. Remove the sunroof window seal (1) from the upper frame (2). 1. Carefully remove the old seal. 2. Open the sunroof window completely when working along the front and sides. 3. Move the sunroof window into the maximum tilt position when working on the rear side. 3. Remove the sunroof window seal from the upper frame. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10947 4. Remove all traces of sealant from around the inside upper frame groove to prevent leaks. 5. Clean the upper frame as follows, clean around the inside surface and edges with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth. Installation Procedure 1. Install a adhesive sealant bead around the outside (1) of the groove of the upper frame 2 mm (1/16 in) thick. 2. Install a adhesive sealant bead only along the front (2), on the inside of the groove 2 mm (1/16 in) thick. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10948 Important: Put the seam of the sunroof window seal in the front under the window holder. This is done to prevent tension in the seal. 3. Place the new sunroof window seal in the frame without pressure. 4. Install the front center under the window holder and push the sunroof window seal from the sides to the rear only 1 mm (1/32 in) into the groove. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10949 5. Install the sunroof window seal entirely into the groove, the seal Must be kept flush fitted in the frame. 6. Remove excessive adhesive sealant from around the sunroof window seal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10950 7. The sunroof must remain open until the adhesive sealant is dry. * Check the curing time on the adhesive sealant. * If the sunroof window has to be close after repair , it is advisable to apply a strip of masking tape in the front center over the seal before closing. This is done to prevent the seal from pulling out of the groove, * When the repairs are completed and cured, water test the vehicle to ensure no leaks. 8. Verify operations of the sunroof window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10955 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10956 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10957 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10958 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments Clutch Switch: Adjustments Clutch Pedal Cruise Control Release Switch Adjustment 1. Disconnect the clutch release switch electrical connector (2). 2. Rotate the clutch release switch (4) counterclockwise, allowing the retainer (5) to release. 3. Pull the clutch pedal to full stop. 4. While holding the clutch pedal at full stop, push the switch (4) inward fully until the switch body contacts the clutch pedal arm. At this point the plunger in the switch (4) should be pushed in. 5. Rotate the switch (4) clockwise until a "click" is heard. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 10962 6. Connect the clutch release switch electrical connector (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 10963 Clutch Switch: Service and Repair Clutch Pedal Cruise Control Release Switch Replacement Removal Procedure 1. Disconnect the clutch release switch electrical connector (2). 2. Complete the following in order to remove the clutch release switch (4) from the clutch pedal bracket (1): 1. Rotate the switch (4) counterclockwise. 2. Pull the switch (4) from the retainer (5). 3. Push the locking tabs inward to release the retainer (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 10964 1. Slide only the clutch release switch retainer (5) into the clutch pedal bracket (1), until the locking tabs are fully engaged. 2. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control Release Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Component Connector End Views Cruise Control Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10968 Cruise Control Switch: Adjustments Cruise Release Switch Adjustment 1. Disconnect the cruise control release switch electrical connector (1). 2. Rotate the cruise release switch counterclockwise, allowing the retainer to release. 3. Pull the brake pedal rearward to full stop. 4. While holding the brake pedal in position rearward, push the switch inward fully until the switch body contacts the brake pedal arm. At this point the plunger in the switch should be pushed in. 5. Rotate the switch clockwise until a "click" is heard. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10969 6. Connect the cruise control release switch electrical connector (1). 7. The switch is properly adjusted when there is 7 mm (0.28 in) clearance between the end of the barrel and the striker plate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10970 Cruise Control Switch: Service and Repair Cruise Control Release Switch Replacement Removal Procedure 1. Disconnect the electrical connector from the cruise release switch. 2. Complete the following in order to remove the cruise release switch from the brake pedal bracket: 1. Rotate the switch counter clockwise. 2. Pull the switch from the retainer. 3. Push the locking tabs inward to release the retainer. Installation Procedure 1. Connect the electrical connector to the cruise release switch. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10971 2. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10976 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10977 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10978 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10979 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments Clutch Switch: Adjustments Clutch Pedal Cruise Control Release Switch Adjustment 1. Disconnect the clutch release switch electrical connector (2). 2. Rotate the clutch release switch (4) counterclockwise, allowing the retainer (5) to release. 3. Pull the clutch pedal to full stop. 4. While holding the clutch pedal at full stop, push the switch (4) inward fully until the switch body contacts the clutch pedal arm. At this point the plunger in the switch (4) should be pushed in. 5. Rotate the switch (4) clockwise until a "click" is heard. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 10983 6. Connect the clutch release switch electrical connector (2). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 10984 Clutch Switch: Service and Repair Clutch Pedal Cruise Control Release Switch Replacement Removal Procedure 1. Disconnect the clutch release switch electrical connector (2). 2. Complete the following in order to remove the clutch release switch (4) from the clutch pedal bracket (1): 1. Rotate the switch (4) counterclockwise. 2. Pull the switch (4) from the retainer (5). 3. Push the locking tabs inward to release the retainer (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 10985 1. Slide only the clutch release switch retainer (5) into the clutch pedal bracket (1), until the locking tabs are fully engaged. 2. Adjust the clutch release switch. Refer to Clutch Pedal Cruise Control Release Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Component Connector End Views Cruise Control Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10989 Cruise Control Switch: Adjustments Cruise Release Switch Adjustment 1. Disconnect the cruise control release switch electrical connector (1). 2. Rotate the cruise release switch counterclockwise, allowing the retainer to release. 3. Pull the brake pedal rearward to full stop. 4. While holding the brake pedal in position rearward, push the switch inward fully until the switch body contacts the brake pedal arm. At this point the plunger in the switch should be pushed in. 5. Rotate the switch clockwise until a "click" is heard. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10990 6. Connect the cruise control release switch electrical connector (1). 7. The switch is properly adjusted when there is 7 mm (0.28 in) clearance between the end of the barrel and the striker plate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10991 Cruise Control Switch: Service and Repair Cruise Control Release Switch Replacement Removal Procedure 1. Disconnect the electrical connector from the cruise release switch. 2. Complete the following in order to remove the cruise release switch from the brake pedal bracket: 1. Rotate the switch counter clockwise. 2. Pull the switch from the retainer. 3. Push the locking tabs inward to release the retainer. Installation Procedure 1. Connect the electrical connector to the cruise release switch. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 10992 2. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10998 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10999 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11000 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11001 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11002 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11003 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11004 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11005 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11006 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11007 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11008 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11009 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11010 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11011 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11012 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11013 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11014 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11015 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11016 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11017 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11018 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11019 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11020 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11021 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11022 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11023 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11024 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11025 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11026 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11027 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11028 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11029 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11030 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11031 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11032 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11033 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11034 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11035 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11036 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11037 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11038 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11039 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11040 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11041 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11042 Cigarette Lighter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11043 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11044 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11045 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11046 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11047 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11048 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11049 may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11050 J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11051 diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11052 - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11053 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11054 The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11055 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11056 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11057 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11058 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11059 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11060 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11061 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11062 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11063 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11064 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11065 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11066 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11067 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11068 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11069 Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11070 marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11071 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11072 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11073 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11074 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11075 Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11076 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11077 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11078 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11079 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11080 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11081 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11082 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11083 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11084 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11085 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11086 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11087 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11088 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics). Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11089 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11090 body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11091 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11092 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11093 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11094 The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11095 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11096 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11097 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11098 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11099 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11100 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11101 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11102 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11103 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11104 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11105 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11106 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11107 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11108 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11109 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11110 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11111 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11112 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11113 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11114 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11115 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11116 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11117 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11118 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11119 J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11120 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11121 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11122 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11123 2. As the slide lever is pulled out the mating connector is lifted from the seated position. 3. Using terminal release tool 12094430 or equivalent, push the TPA tabs into the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11124 4. Pull the TPA from the connector body. Note: TPA is keyed and can only be inserted in one direction. 5. Using terminal release tool 12094430 or equivalent, release the connector wire dress cover locking tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11125 6. With the lock tab released, lift the connector wire dress cover from the connector body. 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11126 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11127 Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11128 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11129 Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. 3. Using terminal tool 12094430 or equivalent, release the wire dress cover locking tabs. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11130 4. Pivot connector wire dress cover while removing from the connector body. 5. Using terminal tool 12094430 or equivalent, remove the TPA by lifting straight off the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11131 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11132 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11133 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11134 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11135 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11136 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure View of a typical connector in the assembled position. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11137 1. Pull the locking lever to the 90 degree position from the connector body. 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11138 3. Slide the male connector body out away from the guide plates. 4. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11139 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11140 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool 12094430 or equivalent to release the locking tab and slide the connector off the female body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11141 9. Move the locking lever 180 degrees from the connected position. 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11142 11. Using terminal release tool 12094430 or equivalent, remove the TPA from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11143 13. Terminal plate will bind slightly on each corner. 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11144 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11145 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11146 19. Slide the male connector body back inward toward the guide plates. 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11147 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11148 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11149 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11150 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Note: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11151 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11152 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11153 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11154 GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * Dura Seal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The Dura Seal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11155 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the Dura Seal splice sleeves on all types of insulation except coaxial. * Do not use the Dura Seal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11156 6. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11157 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any Dura Seal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * Dura Seal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the Dura Seal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11158 Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper Dura Seal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the Dura Seal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the Dura Seal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11159 8. Place the Dura Seal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the Dura Seal splice sleeve in the proper nest. 9. Insert the wire into the Dura Seal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11160 13. Center the high temperature SCT1 shrink tube over the Dura Seal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11161 Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11162 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal Splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11163 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11164 Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Description 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Note: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11165 * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11166 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11167 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11168 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11169 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation Compass Calibration and Magnetic Variance Compass Calibration Before calibrating the compass, drive the vehicle to an open area that is magnetically clean or free of large metallic objects such as high tension power lines or large steel buildings. Verify there are no magnetized roof antennas, magnets on or hanging from the mirror, or any other magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. Important: Before calibrating the compass, make sure the mirror has the correct zone number. Refer to Compass Magnetic Variation Adjustment. 2. Press and hold the switch for the compass, which may be depicted as compass/temperature or COMP, depending on the type of mirror on the vehicle, until the letter "C" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" is replaced by a proper vehicle heading. The calibration procedure is now complete. Compass Magnetic Variation Adjustment Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. World Magnetic Variation Map 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as compass/temperature or COMP, depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Release and press the switch again until the desired zone number appears. 5. Release and wait 4 seconds. The display will return to a compass heading. The variance procedure is now complete. 6. Calibrate the compass. Refer to Compass Calibration mentioned above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 11177 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Harness Routing Views Dimmer Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11182 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11183 Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Page 11184 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Indicator Description and Operation Door Ajar Indicator The instrument panel cluster (IPC) illuminates the door ajar indicator when the body control module (BCM) detects any of the 4 vehicle doors is open. The IPC receives a class 2 message from the BCM requesting illumination. The IPC sends a class 2 message to the radio in order to activate an audible warning. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views Door Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11192 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11193 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Left Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11194 1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver Right Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11195 1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right Rear Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11196 Door Switch: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left B-Pillar Components (Regular Cab) 1 - Door Jamb Switch - Driver Left B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11197 1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver Right B-Pillar Components (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11198 1 - Door Jamb Switch - Passenger Right B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11199 1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11200 Door Switch: Locations Door Component Views Door Component Views Left Rear Door Frame Components (Extended Cab) 1 - Door Jamb Switch - Driver Right Rear Door Frame Components (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Harness Routing Views > Page 11201 1 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 11202 Door Switch: Diagrams Component Connector End Views Door Jamb Switch - Driver Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 11203 Door Jamb Switch - Left Rear (Crew Cab) Door Jamb Switch - Right Rear (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 11204 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 11205 Door Switch: Service and Repair Door Jamb Switch Replacement Removal Procedure 1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch. Installation Procedure 1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 11206 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw retaining the door jam switch to the body. Tighten the door jamb switch screw to 1.5 Nm (13 lb in). 4. Close the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation Driver Information Center (DIC) The driver information center (DIC) consists of a double line 14 character display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using a control stem. Pressing the stem for 1 second will display the DIC options. Pressing the stem for more than 2 seconds will select an option. DIC Displays The driver information center (DIC) parameters are displayed by order of priority as follows (from highest to lowest) : * Service Diagnostics * Feature Programming * Driver Warnings * Vehicle Information Vehicle Information Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance or related information. When the English/Metric status changes, any applicable vehicle information data values will also change. Odometer The odometer is capable of displaying values from 0-999,999 KM or MI. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip/reset switch. The odometer will remain displayed for 5 seconds. Trip Odometers The trip odometer is capable of displaying values from 0-9999.9 KM or MI. When the maximum value is reached, the trip odometer will roll over to 0.0. Holding the control stem for greater than 4 seconds while the trip odometer is displayed will reset the displayed trip odometer to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. Engine Oil Life Engine Oil Life percentage values are based on serial data messages to the instrument panel cluster (IPC). The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0 to 100%. Pressing the control stem for longer than 2 seconds while Engine Oil Life is displayed on the DIC will reset the value to 100%. An audible warning will sound confirming that the system has been reset. Display appears as OIL LIFE: XXX%. Display Language The driver information center (DIC) is capable of displaying messages in more than one language. The DIC language selection procedure is as follows: 1. With the engine OFF, turn the key to ON, but do not start the engine. 2. Close all doors so the DOORS message does not display in the DIC. 3. Momentarily press and release the trip reset stem until the current language is displayed: English, French or Spanish. 4. To select a different language, press and hold the trip reset stem until the next language appears. 5. Repeat Step 4 until the desired language is displayed. Once the desired language is shown on the DIC display, the language is set. 6. To exit language selection, momentarily press and release the trip stem. All DIC messages will now display in the language selected. Feature Programming Refer to Personalization Description and Operation (See: Accessories and Optional Equipment/Description and Operation/Personalization Description and Operation). Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation (See: Description and Operation/Indicator/Warning Message Description and Operation). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 11217 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11222 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11223 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11224 Customer TPMS Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11225 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11226 Frequently Asked Questions Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Cluster Schematics) * Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (See: Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 11233 * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 11238 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 11239 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 11240 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair GM Oil Life System Resetting The vehicle has a computer system that has a change engine oil message, indicating when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the kilometers or mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. The change engine oil message will come on. The oil must be changed as soon as possible. It is possible that, if the vehicle is driven under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil and filter is changed. Resetting Procedure 1. Turn the ignition to RUN with the engine OFF. 2. Press and release the reset stem in the lower center of the instrument panel (I/P) cluster until the OIL LIFE message is displayed. 3. Once the alternating OIL LIFE and RESET messages appears in the display, press and hold the reset stem until several beeps sound. This confirms the OIL LIFE system has been reset. 4. Turn the key to lock. If the CHANGE OIL message comes back on when you start the engine, the ENGINE OIL LIFE system has not reset. Repeat the procedure. Alternate Method 1. Turn the ignition key to RUN with the engine off. 2. Fully press the release the accelerator pedal 3 times within 5 seconds. Several beeps sound. This confirms the oil life system has been reset. 3. If the CHANGE/OIL message comes back on when you start the engine, the engine oil life system has not been reset. Repeat the procedure. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine - Left (LH8) 1 - Engine Coolant Temperature (ECT) Sensor 2 - Generator 3 - Ignition Coil 1 4 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 5 - Ignition Coil 3 6 - Ignition Coil 5 7 - Ignition Coil 7 8 - Engine Oil Pressure (EOP) Sensor 9 - Park/Neutral Position (PNP) Switch (M30) 10 Knock Sensor (KS) 1 11 - Engine Block Heater Connector (K05) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 11247 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LH8) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Outside Temperature Display Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 11253 Outside Temperature Display Sensor: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 11254 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 11255 Outside Temperature Display Sensor: Service and Repair Ambient Air Temperature Sensor Replacement Removal Procedure 1. Remove the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 2. Disconnect the electrical connector to the ambient air temperature sensor. 3. Release the tabs (1) retaining the sensor to the radiator support bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 11256 4. Remove the sensor (1) from the radiator support bracket. Installation Procedure 1. Position the sensor (1) to the radiator support bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 11257 2. Install the sensor ensuring the retaining tabs (1) are fully seated to the radiator support bracket. 3. Connect the electrical connector to the ambient air temperature sensor. 4. Install the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard / Instrument Panel/Service and Repair). 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Page 11261 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in). 3. Install the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Page 11262 4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views Dimmer Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11268 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11269 Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 11270 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views Door Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11275 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11276 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Left Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11277 1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver Right Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11278 1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right Rear Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11279 Door Switch: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left B-Pillar Components (Regular Cab) 1 - Door Jamb Switch - Driver Left B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11280 1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver Right B-Pillar Components (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11281 1 - Door Jamb Switch - Passenger Right B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11282 1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11283 Door Switch: Locations Door Component Views Door Component Views Left Rear Door Frame Components (Extended Cab) 1 - Door Jamb Switch - Driver Right Rear Door Frame Components (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Harness Routing Views > Page 11284 1 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 11285 Door Switch: Diagrams Component Connector End Views Door Jamb Switch - Driver Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 11286 Door Jamb Switch - Left Rear (Crew Cab) Door Jamb Switch - Right Rear (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 11287 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 11288 Door Switch: Service and Repair Door Jamb Switch Replacement Removal Procedure 1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch. Installation Procedure 1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 11289 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw retaining the door jam switch to the body. Tighten the door jamb switch screw to 1.5 Nm (13 lb in). 4. Close the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Outside Temperature Display Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - Ambient Air Temperature (AAT) Sensor (DF8) 2 - Horn Assembly 3 - Inflatable Restraint Front End Sensor - Left 4 - Inflatable Restraint Front End Sensor - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 11297 Outside Temperature Display Sensor: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 - Horn Assembly 2 - Fuse Block - Underhood X1 3 - X108 (Forward Lamp Harness to Front Turn Signal Harness) 4 - Headlamp - LH (-TT5) 5 - Headlamp - Low Beam - Left (TT5) 6 - Headlamp High Beam - Left (TT5) 7 - Fog Lamp - Left Front (T96) 8 - Inflatable Restraint Front End Sensor Left 9 - Ambient Air Temperature Sensor (DF8) 10 - Inflatable Restraint Front End Sensor - Right 11 - Fog Lamp - Right Front (T96) 12 - Headlamp - High Beam - Right (TT5) 13 - Headlamp - Low Beam - Right (TT5) 14 - Headlamp - RH (-TT5) 15 - X104 (Forward Lamp Harness to Body Harness) 16 - X103 (Forward Lamp Harness to Body Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 11298 17 - X107 (Forward Lamp Harness to Front Turn Signal Harness) 18 - Forward Lamp Harness (TT5) 19 - Forward Lamp Harness (-TT5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 11299 Outside Temperature Display Sensor: Service and Repair Ambient Air Temperature Sensor Replacement Removal Procedure 1. Remove the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 2. Disconnect the electrical connector to the ambient air temperature sensor. 3. Release the tabs (1) retaining the sensor to the radiator support bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 11300 4. Remove the sensor (1) from the radiator support bracket. Installation Procedure 1. Position the sensor (1) to the radiator support bracket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 11301 2. Install the sensor ensuring the retaining tabs (1) are fully seated to the radiator support bracket. 3. Connect the electrical connector to the ambient air temperature sensor. 4. Install the air inlet grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard / Instrument Panel/Service and Repair). 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 11305 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch mounting bolt and tighten to 4 Nm (35 lb in). 3. Install the electrical connector. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 11306 4. Install the knee bolster trim panel. Refer to Knee Bolster Replacement (See: Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11312 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11313 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11314 Customer TPMS Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11315 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 11316 Frequently Asked Questions Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11329 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11330 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11331 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11332 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11333 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting. * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 11336 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting. * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the body control module (BCM) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 11337 Tire Pressure Sensor: Service and Repair Tire Valve Stem Grommet Replacement Tire Valve Stem Grommet Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * Position the bead breaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the outside of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, replace the sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Tire Pressure Indicator Sensor Replacement). Also remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the sensor from the wheel hole. 6. Remove the sensor grommet from the valve stem. Installation Procedure 1. Clean any dirt or debris from the grommet sealing areas. 2. Install the grommet on the sensor valve stem. 3. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement > Page 11338 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note: Before installing the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 5. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 6. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11344 Ambient Light Sensor: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11345 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11346 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11347 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Removal Procedure 1. Carefully use a flat-bladed tool, and remove the sensor from the upper portion of the instrument panel (I/P). 2. Disconnect the electrical connector (2) from the sensor ensuring the connector does NOT fall through the hole in the I/P. 3. Remove the sensor from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11348 1. Connect the electrical connector (2) to the sensor. 2. Align the sensor to the I/P for installation. 3. Apply downward pressure to the sensor head in order to seat the sensor to the I/P. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Powertrain Component Views Right Side of the Transmission Components (MA5) 1 - Backup Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 11353 Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 11354 Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the backup lamp switch electrical connector (1) at the pigtail. 3. Open the tie strap securing the pigtail to the transmission. 4. Remove the backup lamp switch with the aluminum washer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 11355 Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install the backup lamp switch with a NEW aluminum washer into the transmission case. Tighten the backup lamp switch to 44 Nm (32 lb ft). 2. Secure the pigtail to the transmission with the tie strap. 3. Connect the backup lamp switch electrical connector (1) at the pigtail. 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair Backup Lamp Bulb Replacement Removal Procedure 1. Open the tailgate. 2. Remove the screws (1) from the tail lamp assembly. 3. Remove the lamp assembly. 4. Remove the tail lamp and backup lamp sockets, depressing the locking tab and rotating counterclockwise. 5. Remove the bulbs from the backup lamp sockets. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair > Page 11359 1. Install the bulbs to the backup lamp sockets. 2. Install the backup lamp rotating clockwise until the locking tab is fully seated. 3. Press the tail lamp to the rear body panel until fully seated. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the tail lamp screws (1) to the tail lamp. Tighten the tail lamp screws (1) to 3 Nm (26 lb in). 5. Close the tailgate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11369 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11370 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11371 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11372 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11377 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11378 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > Recalls for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11379 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11385 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11386 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11387 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11388 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11393 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11394 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Bulb: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11395 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11404 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11405 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11406 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11407 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11412 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11413 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11414 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect Brake Light Switch: Recalls Recall 09V310000: Brake Lamp Switch Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon 2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: July 28, 2009 NHTSA CAMPAIGN ID NUMBER: 09V310000 NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 185903 SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year 2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290, and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. REMEDY: Dealers will inspect and replace the necessary components as specified in the recall bulletin free of charge. GM anticipates that parts will be available by February 2010. A special coverage for vehicles registered in all other states will be implemented in the same time frame. In the interim, owners who experience the failure can obtain a free repair, however they will be required to return when the new design part becomes available. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at www.gmownercenter.com. NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11424 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11425 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11426 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11427 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11432 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11433 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11434 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect Brake Light Switch: All Technical Service Bulletins Recall 09V310000: Brake Lamp Switch Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon 2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: July 28, 2009 NHTSA CAMPAIGN ID NUMBER: 09V310000 NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 185903 SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year 2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290, and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. REMEDY: Dealers will inspect and replace the necessary components as specified in the recall bulletin free of charge. GM anticipates that parts will be available by February 2010. A special coverage for vehicles registered in all other states will be implemented in the same time frame. In the interim, owners who experience the failure can obtain a free repair, however they will be required to return when the new design part becomes available. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at www.gmownercenter.com. NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11439 Brake Light Switch: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11440 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11441 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11442 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11443 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11444 Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11445 Brake Light Switch: Adjustments Stop Lamp Switch Adjustment 1. Rotate the switch counterclockwise, allowing the retainer to release. 2. Pull the brake pedal rearward to full stop. Important: Do not move the brake pedal during switch adjustment as this will cause an over-adjusted switch which could cause brake drag. 3. While holding the brake pedal FIRMLY in position rearward, push the switch inward fully until the switch body contacts the brake pedal arm striker plate. At this point the plunger in the switch should be pushed in. 4. Rotate the switch clockwise until a "click" is heard. 5. The switch is properly adjusted when there is 7 mm (0.028 in) clearance between the end of the switch barrel and the striker plate on the brake pedal arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11446 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the stop lamp switch electrical connectors (1). 2. Rotate the switch counterclockwise. 3. Remove the switch from the bracket. 4. Remove the switch from the vehicle. Installation Procedure 1. Position the switch near the bracket. 2. Ensure the switch key-way is properly indexed to the plastic retainer. 3. Install and adjust the switch. Refer to Stop Lamp Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11447 4. Connect the stop lamp switch electrical connectors (1). 5. Check the switch for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Cargo Lamp: Diagrams Component Connector End Views Cargo Lamp - Left Cargo Lamp - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair High Mount Stop Lamp Bulb Replacement Removal Procedure 1. Remove the screws that retain the center high-mounted stop lamp (CHMSL) lens to the vehicle. 2. Remove the CHMSL from the vehicle. 3. Twist the lamp sockets (1) counterclockwise to remove. 4. Remove the bulbs from the sockets. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Page 11455 1. Install the CHMSL bulbs (1). 2. Install the CHMSL assembly to the vehicle. Ensure that the CHMSL gasket is seated properly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screws that retain the CHMSL lens to the vehicle. Tighten the screws to 2.5 Nm (22 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams Courtesy Lamp: Diagrams Component Connector End Views I/P Courtesy Lamp - Left I/P Courtesy Lamp - Right Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Page 11459 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Harness Routing Views Dimmer Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11464 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Harness Routing Views > Page 11465 Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 11466 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams Dome Lamp: Diagrams Component Connector End Views Dome Lamp Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 11470 Dome Lamp: Service and Repair Dome Lamp Replacement Removal Procedure 1. Remove the lens from the dome lamp. 2. Carefully use a flat-bladed tool, and release the tabs (2) retaining to the dome lamp to the headliner. 3. Lower the dome lamp and disconnect the electrical connector (1). 4. Remove the dome lamp from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 11471 1. Position the dome lamp to the headliner and connect the electrical connector (1). 2. Ensure the retaining tabs (2) are in the open position. 3. Install the dome lamp into the headliner opening and close the retaining tabs (2). 4. Ensure the dome lamp is secure to the headliner. 5. Install the lens to the dome lamp. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views Door Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11476 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11477 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Left Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11478 1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver Right Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11479 1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right Rear Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11480 Door Switch: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left B-Pillar Components (Regular Cab) 1 - Door Jamb Switch - Driver Left B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11481 1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver Right B-Pillar Components (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11482 1 - Door Jamb Switch - Passenger Right B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11483 1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11484 Door Switch: Locations Door Component Views Door Component Views Left Rear Door Frame Components (Extended Cab) 1 - Door Jamb Switch - Driver Right Rear Door Frame Components (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11485 1 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11486 Door Switch: Diagrams Component Connector End Views Door Jamb Switch - Driver Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11487 Door Jamb Switch - Left Rear (Crew Cab) Door Jamb Switch - Right Rear (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11488 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11489 Door Switch: Service and Repair Door Jamb Switch Replacement Removal Procedure 1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch. Installation Procedure 1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11490 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw retaining the door jam switch to the body. Tighten the door jamb switch screw to 1.5 Nm (13 lb in). 4. Close the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair Front Fog Lamp Bulb Replacement (Colorado) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Harness Routing Views Hazard Warning Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Harness Routing Views > Page 11503 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Harness Routing Views > Page 11504 Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 11505 Hazard Warning Switch: Diagrams Component Connector End Views Hazard Warning Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 11506 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Disconnect the hazard switch electrical connector. Important: Ensure the tabs retaining the switch to the trim plate are released from the back side of the trim panel. 3. Release the tabs retaining the switch to the trim plate. 4. Remove the switch (1) from the trim plate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 11507 Installation Procedure 1. Position the switch (1) to the trim plate. 2. Ensure the switch key-way is indexed to the trim plate. 3. Install the switch to the trim plate ensuring the tabs are fully seated. 4. Connect the hazard switch electrical connector. 5. Install the I/P accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair Headlamp Bulb Replacement Removal Procedure Warning Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: * Turn off the lamp switch and allow the bulb to cool before changing the bulb. * Leave the lamp switch OFF until the bulb change is complete. * Always wear eye protection when changing a halogen bulb. * Handle the bulb only by its base. Avoid touching the glass. * Keep dirt and moisture off the bulb. * Properly dispose of the used bulb. * Keep halogen bulbs out of the reach of children. Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in the LOCK position. 3. Remove the front grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). 4. Remove the bolts that retain the headlamp. 5. Push and rotate the high beam headlamp (2), low beam headlamp (3) 1/4 turn counterclockwise in order to remove the bulb, if needed. 6. Disconnect the electrical connector. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11512 1. Connect the electrical connector to the bulb. 2. Push in and rotate the high beam headlamp (2), low beam headlamp (3) 1/4 turn clockwise in order to install the bulb. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts that retain the headlamp. Tighten the bolts to 10 Nm (89 lb in). 4. Inspect the headlamps for proper operation. 5. Install the front grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views Headlamp Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11524 Headlamp Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11525 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11526 Headlamp Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11527 Headlamp Switch: Service and Repair Headlamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the screw retaining the switch to the instrument panel (I/P). 3. Partially remove the switch from the I/P. 4. Disconnect the switch electrical connector. 5. Remove the switch from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11528 1. Position the switch to the I/P. 2. Connect the electrical connector to the switch. 3. Install the switch to the I/P. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screw retaining the switch to the I/P. Tighten the screw to 2.5 Nm (22 lb in). 5. Install the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations High Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations Low Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component Connector End Views Horn Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 11542 Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Removal Procedure Warning: Refer to Servicing the SIR System Warning (See: Restraint Systems/Service Precautions/Servicing the SIR System Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the Inflatable Restraint Steering Wheel module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 3. Remove the horn plunger from the steering column by pressing inward to the stop and by rotating the plunger 90 degrees. 4. Disconnect the screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Connect the screws (1, 4) that secure the contact plate to the steering wheel (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 11543 Tighten the screws to 5.5 Nm (49 lb in). 3. Install the horn plunger to the steering column. 4. Install the inflator module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair License Lamp Bulb Replacement Removal Procedure 1. Ensure the headlamp switch is in the OFF position. 2. Disconnect the electrical connector (2) from the license lamp assembly (1). 3. Remove the nut (3) retaining the license lamp to the bumper. 4. Remove the license lamp assembly from the bumper. 5. Twist the lamp socket counterclockwise to remove. 6. Remove the bulb. Installation Procedure 1. Install the bulb to the lamp socket. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > Page 11548 2. Twist the lamp socket clockwise to install. 3. Install the lamp assembly (1) into the bumper. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the license lamp nut (3). Tighten the nut to 2.5 Nm (22 lb in). 5. Install the electrical connector (2). 6. Inspect the lamp operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair Park/Turn Signal/Side Marker Lamp Bulb Replacement Removal Procedure Warning Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: * Turn off the lamp switch and allow the bulb to cool before changing the bulb. * Leave the lamp switch OFF until the bulb change is complete. * Always wear eye protection when changing a halogen bulb. * Handle the bulb only by its base. Avoid touching the glass. * Keep dirt and moisture off the bulb. * Properly dispose of the used bulb. * Keep halogen bulbs out of the reach of children. Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in the LOCK position. 3. Open the hood. 4. Release the locking tab (1) on the park, turn, daytime running lamp assembly by using a flat-bladed tool and pushing the tab on the lamp outward toward the fender. 5. Rotate the outward edge of the lamp assembly forward. 6. Release the park/turn signal lamp socket (2) by rotating the socket a quarter turn counter-clockwise. 7. Remove the park, turn signal lamp bulb (3). 8. Repeat steps 6 and 7 for the daytime running lamp socket (4) and bulb (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Page 11553 1. Secure the bulbs (3,5) into the bulb sockets (2,4) and to the lamp assembly. 2. Insert the inside edge of the lamp tabs to the grille support. 3. Rotate the lamp assembly into the fender bracket. 4. Push on the outboard edge of the lamp until an audible click is heard, when the lamp assembly is secure to the fender. 5. Inspect the lamps for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair Park/Turn Signal/Side Marker Lamp Bulb Replacement Removal Procedure Warning Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: * Turn off the lamp switch and allow the bulb to cool before changing the bulb. * Leave the lamp switch OFF until the bulb change is complete. * Always wear eye protection when changing a halogen bulb. * Handle the bulb only by its base. Avoid touching the glass. * Keep dirt and moisture off the bulb. * Properly dispose of the used bulb. * Keep halogen bulbs out of the reach of children. Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in the LOCK position. 3. Open the hood. 4. Release the locking tab (1) on the park, turn, daytime running lamp assembly by using a flat-bladed tool and pushing the tab on the lamp outward toward the fender. 5. Rotate the outward edge of the lamp assembly forward. 6. Release the park/turn signal lamp socket (2) by rotating the socket a quarter turn counter-clockwise. 7. Remove the park, turn signal lamp bulb (3). 8. Repeat steps 6 and 7 for the daytime running lamp socket (4) and bulb (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 11561 1. Secure the bulbs (3,5) into the bulb sockets (2,4) and to the lamp assembly. 2. Insert the inside edge of the lamp tabs to the grille support. 3. Rotate the lamp assembly into the fender bracket. 4. Push on the outboard edge of the lamp until an audible click is heard, when the lamp assembly is secure to the fender. 5. Inspect the lamps for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations Low Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Service and Repair Trailer Lighting Module: Service and Repair Trailer Lamp Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11589 Ambient Light Sensor: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11590 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11591 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11592 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Removal Procedure 1. Carefully use a flat-bladed tool, and remove the sensor from the upper portion of the instrument panel (I/P). 2. Disconnect the electrical connector (2) from the sensor ensuring the connector does NOT fall through the hole in the I/P. 3. Remove the sensor from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11593 1. Connect the electrical connector (2) to the sensor. 2. Align the sensor to the I/P for installation. 3. Apply downward pressure to the sensor head in order to seat the sensor to the I/P. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Powertrain Component Views Right Side of the Transmission Components (MA5) 1 - Backup Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 11597 Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (MA5) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 11598 Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the backup lamp switch electrical connector (1) at the pigtail. 3. Open the tie strap securing the pigtail to the transmission. 4. Remove the backup lamp switch with the aluminum washer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 11599 Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 1. Install the backup lamp switch with a NEW aluminum washer into the transmission case. Tighten the backup lamp switch to 44 Nm (32 lb ft). 2. Secure the pigtail to the transmission with the tie strap. 3. Connect the backup lamp switch electrical connector (1) at the pigtail. 4. Lower the vehicle. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11608 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11609 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11610 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09049A > Mar > 11 > Recall Brake Lamps Inoperative/Continuously ON > Page 11611 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 11616 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 11617 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09186B > Mar > 11 > Campaign Brake Lamps Inoperative Or Continuously On > Page 11618 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect Brake Light Switch: Recalls Recall 09V310000: Brake Lamp Switch Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon 2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: July 28, 2009 NHTSA CAMPAIGN ID NUMBER: 09V310000 NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 185903 SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year 2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290, and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. REMEDY: Dealers will inspect and replace the necessary components as specified in the recall bulletin free of charge. GM anticipates that parts will be available by February 2010. A special coverage for vehicles registered in all other states will be implemented in the same time frame. In the interim, owners who experience the failure can obtain a free repair, however they will be required to return when the new design part becomes available. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at www.gmownercenter.com. NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON Technical Service Bulletin # 09049A Date: 110314 Recall - Brake Lamps Inoperative/Continuously ON SAFETY Bulletin No.: 09049A Date: March 14, 2011 Subject: 09049A - Brake Lamps Inoperative or Continuous Illumination Models: 2004-2009 Chevrolet Colorado 2004-2009 GMC Canyon Registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, Utah Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s). Please discard all copies of bulletin 09049, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control could become inoperative. Correction Dealers are to install a new brake lamp switch assembly. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles registered in Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands, and Utah, and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11628 The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by August 31, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11629 * The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter (Letter sent to customers in Phase 1 Notification) Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11630 continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? The brake lamp switch in your vehicle may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if equipped, the cruise control will become inoperative. What will we do? When parts are available after August 2, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment on or after August 2, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the Owner Center at www.gmownercenter.com. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049 Division Owner Letter Division Owner Letter (Letter sent to customer in Phase 2 notification) Dear General Motors Customer: Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09049A > Mar > 11 > Recall - Brake Lamps Inoperative/Continuously ON > Page 11631 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 09049. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? Your vehicle may have a brake lamp switch that may not work as designed due to contamination in the switch. Performance of the brakes is not affected. However, this condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. Also, if your vehicle has cruise control, it could become inoperative. What will we do? When parts are available after August 26, 2010, your GM dealer will install a new brake lamp switch assembly. This service will be performed for you at no charge. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment onor after August 26, 2010. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition corrected, you will still need to take your vehicle to your GM dealer for additional repairs. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 09049-2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On Technical Service Bulletin # 09186B Date: 110314 Campaign - Brake Lamps Inoperative Or Continuously On SPECIAL COVERAGE Bulletin No.: 09186B Date: March 14, 2011 Subject: 09186B - SPECIAL COVERAGE ADJUSTMENT - BRAKE LAMPS INOPERATIVE OR CONTINUOUS ILLUMINATION Models: 2004-2009 CHEVROLET COLORADO 2004-2009 GMC CANYON Supercede: The Part Information, Service Procedure, and Warranty Transaction Information sections in this bulletin have been revised to include the replacement of burned out brake lamp bulb(s).Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin.Please discard all copies of bulletin 09186A, issued October 2010. Condition Some customers of 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may comment about the loss of brake lamps or continuous illumination of the brake lamps. This may be caused by contamination in the brake lamp switch. The performance of the brakes is not affected. Also, if equipped, they may comment about the loss of cruise control. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new brake lamp switch assembly. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles built within the following VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11636 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). * Part number 20913529 was used in Safety Recall 09049 and most dealers will have a supply of these switches on their shelves. Please verify your dealer inventory before ordering additional quantities. Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Prior to performing this repair, check to see if the vehicle is involved in Safety Recall 06030. If the vehicle is involved in Safety Recall 06030 and the repair has not been performed, perform the repair using Safety Recall 06030 (labor code V1508). If the vehicle is not involved in the safety recall or has already had the safety recall performed, proceed with repairs using this Special Coverage bulletin. 1. Remove the stop lamp switch from the vehicle. Refer to Stop Lamp Replacement in SI. 2. Install a new stop lamp switch. Refer to Stop Lamp Replacement in SI. 3. If the brake lamp bulb(s) require replacement, refer to Tail Lamp Assembly and/or Backup, Side Marker, Stop, Turn Signal Bulb Replacement in SI. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2011. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11637 the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Disclaimer Owner Letter Owner Letter Dear GM Customer: As the owner of a 2004-2009 model year Chevrolet Colorado or GMC Canyon vehicles, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2004-2009 model year Chevrolet Colorado and GMC Canyon vehicles may have a condition where contamination in the brake lamp switch could cause the loss of brake lamps or continuous illumination of the brake lamps. The performance of the brakes is not affected. Also, if your vehicle is equipped with cruise control, it may become inoperative. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners with additional protection for the brake lamp switch. If this condition occurs on your 2004-2009 Chevrolet Colorado or GMC Canyon vehicle within 7 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. If you believe your vehicle has the condition described above, you may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by December 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. General Motors Corporation Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09186B > Mar > 11 > Campaign - Brake Lamps Inoperative Or Continuously On > Page 11638 Enclosure 09186 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > NHTSA09V310000 > Jul > 09 > Recall 09V310000: Brake Lamp Switch Defect Brake Light Switch: All Technical Service Bulletins Recall 09V310000: Brake Lamp Switch Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Colorado 2004-2009 GMC/Canyon 2004-2009 Isuzu/I-280 2006 Isuzu/I-290 2007-2008 Isuzu/I-350 2006 Isuzu/I-370 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: July 28, 2009 NHTSA CAMPAIGN ID NUMBER: 09V310000 NHTSA ACTION NUMBER: RQ09001 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 185903 SUMMARY: GM is recalling 185,903 model year 2004-2009 Chevrolet Colorado, Model year 2004-2009 GMC Canyon, model year 2006 Isuzu I-280, I-350, model year 2007-2008 Isuzu I-290, and I-370, passenger vehicles originally sold in or currently registered in the states of Alabama, Arizona, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Puerto Rico, South Carolina, Texas, U.S. Virgin Islands and Utah. Some of these vehicles have a brake lamp switch that may not work as designed due to contamination in the switch. CONSEQUENCE: This condition could cause the simultaneous loss of all brake lamps or cause all of the brake lamps to stay on continuously. Both of these conditions could fail to warn others of the driver's intentions and could lead to a vehicle crash. REMEDY: Dealers will inspect and replace the necessary components as specified in the recall bulletin free of charge. GM anticipates that parts will be available by February 2010. A special coverage for vehicles registered in all other states will be implemented in the same time frame. In the interim, owners who experience the failure can obtain a free repair, however they will be required to return when the new design part becomes available. Owners may contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727 or at www.gmownercenter.com. NOTES: GM recall No. 09049. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11643 Brake Light Switch: Locations Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11644 19 - J303 20 - Clutch Switch 21 - Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 - Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Extended Cab) 1 - X310 (Dome Lamp Harness to Body Harness) 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X313 (Body Harness to Passenger Seat Harness) 7 - X317 (Body Harness to RR Passenger Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11645 8 - X312 (Body Harness to RR Passenger Door Harness) 9 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 10 - X316 (Body Harness to LR Passenger Door Harness) 11 - X311 (Body Harness to LR Passenger Door Harness) 12 - X314 (Body Harness to Driver Seat Harness) 13 Transfer Case Shift Control Module X1 14 - Transfer Case Shift Control Module X2 15 - G Sensor 16 - G300 17 - Accelerator Pedal position (APP) Sensor 18 - J102 19 - J100 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - Clutch Switch 24 Inflatable Restraint Roof Rail Module - Right 25 - X211 (A31) (Body Harness to Passenger Door Harness) 26 - X210 (A31) (Body Harness to Passenger Door Harness) 27 - X200 (I/P Harness to Body Harness) 28 - X275 (Body Harness to Steering Wheel Harness) 29 - Clutch Start Switch (MA5) 30 - Body Control Module (BCM) X1 31 - X209 (Body Harness to Driver Door Harness) 32 X202 (Body Harness to Driver Door Harness) 33 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11646 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner - Right Front 10 - Door Jamb Switch Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch - Left Rear 16 - Door Jamb Switch - Driver 17 Transfer Case Shift Control Module X1 and X2 18 - G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11647 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11648 Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11649 Brake Light Switch: Adjustments Stop Lamp Switch Adjustment 1. Rotate the switch counterclockwise, allowing the retainer to release. 2. Pull the brake pedal rearward to full stop. Important: Do not move the brake pedal during switch adjustment as this will cause an over-adjusted switch which could cause brake drag. 3. While holding the brake pedal FIRMLY in position rearward, push the switch inward fully until the switch body contacts the brake pedal arm striker plate. At this point the plunger in the switch should be pushed in. 4. Rotate the switch clockwise until a "click" is heard. 5. The switch is properly adjusted when there is 7 mm (0.028 in) clearance between the end of the switch barrel and the striker plate on the brake pedal arm. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11650 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure 1. Disconnect the stop lamp switch electrical connectors (1). 2. Rotate the switch counterclockwise. 3. Remove the switch from the bracket. 4. Remove the switch from the vehicle. Installation Procedure 1. Position the switch near the bracket. 2. Ensure the switch key-way is properly indexed to the plastic retainer. 3. Install and adjust the switch. Refer to Stop Lamp Switch Adjustment (See: Adjustments). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 11651 4. Connect the stop lamp switch electrical connectors (1). 5. Check the switch for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views Door Switch: Locations Harness Routing Views Harness Routing Views Body Harness Routing 2 of 3 (Regular Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 6 - Door Jamb Switch - Front Passenger 7 - X313 (Body Harness to Passenger Seat Harness) 8 - Seat Belt Pretensioner - Right Front 9 Inflatable Restraint Sensing and Diagnostic Module (SDM) 10 - Transfer Case Shift Control Module 11 - X314 (Body Harness to Driver Seat Harness) 12 - G Sensor 13 - Seat Belt Pretensioner - Left Front 14 - Door Jamb Switch - Driver 15 - G300 16 - Stop Lamp Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11659 17 - TCC Brake/Cruise Release Switch 18 - Park Brake Switch 19 - J303 20 - Clutch Switch 21 Clutch Start Switch 22 - X208 (I/P Harness to Body Harness) 23 - X202 (Driver Door Harness to Body Harness) 24 - C209 (Body Harness to Driver Door Harness) 25 - C200 (I/P Harness to Body Harness) 26 - C275 (Body Harness to Steering Wheel Harness) 27 - Inflatable Restraint Roof Rail Module - Left 28 - Accelerator Pedal Position (APP) Sensor 29 - C310 (Dome Lamp Harness to Body Harness) 30 - C210 and C211 (A31) (Body Harness to Passenger Door Harness) 31 Inflatable Restraint Roof Rail Module - Right 32 - Inside Rearview Mirror Body Harness Routing 2 of 3 (Crew Cab) 1 - Body Control Module (BCM) X1 2 - X201 (I/P Harness to Body Harness) 3 - G301 4 - G302 5 Inflatable Restraint Sensing and Diagnostic Module (SDM) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11660 6 - X317 (Body Harness to Right Rear Passenger Door Harness) 7 - Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) 8 - Door Jamb Switch - Front Passenger 9 - Seat Belt Pretensioner Right Front 10 - Door Jamb Switch - Right Rear 11 - X313 (Body Harness to Passenger Seat Harness) 12 - X316 (Body Harness to Left Rear Passenger Door Harness) 13 - X314 (Body Harness to Driver Seat Harness) 14 - Seat Belt Pretensioner - Left Front 15 - Door Jamb Switch Left Rear 16 - Door Jamb Switch - Driver 17 - Transfer Case Shift Control Module X1 and X2 18 G Sensor 19 - G300 20 - Stop Lamp Switch 21 - TCC Brake/Cruise Release Switch 22 - Park Brake Switch 23 - J303 24 - Clutch Switch 25 - Clutch Start Switch 26 - X208 (I/P Harness to Body Harness) 27 - X202 (Driver Door Harness to Body Harness) 28 - X209 (Body Harness to Driver Door Harness) 29 - X200 (I/P Harness to Body Harness) 30 - X275 (Body Harness to Steering Wheel Harness) 31 - Inflatable Restraint Roof Rail Module - Left 32 - Accelerator Pedal Position (APP) Sensor 33 - X310 (Dome Lamp Harness to Body Harness) 34 - X210 and X211 (A31) (Body Harness to Passenger Door Harness) 35 - Inflatable Restraint Roof Rail Module - Right 36 - Inside Rearview Mirror Left Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11661 1 - Speaker - Left Rear Door 2 - X312 (Body Harness to Left Rear Door Harness) 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Seat Belt Pretensioner - Left Front 5 - Door Jamb Switch Driver Right Rear Door Harness Routing (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11662 1 - Speaker - Right Rear Door 2 - Door Jamb Switch - Front Passenger 3 - Seat Belt Pretensioner Right Front 4 - X317 (Body Harness to Right Rear Door Harness) 5 - X311 (Body Harness to Right Rear Door Harness) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11663 Door Switch: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left B-Pillar Components (Regular Cab) 1 - Door Jamb Switch - Driver Left B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11664 1 - Door Jamb Switch - Left Rear 2 - Door Jamb Switch - Driver Right B-Pillar Components (Regular Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11665 1 - Door Jamb Switch - Passenger Right B-Pillar and C-Pillar Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11666 1 - Door Jamb Switch - Right Rear 2 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11667 Door Switch: Locations Door Component Views Door Component Views Left Rear Door Frame Components (Extended Cab) 1 - Door Jamb Switch - Driver Right Rear Door Frame Components (Extended Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Harness Routing Views > Page 11668 1 - Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11669 Door Switch: Diagrams Component Connector End Views Door Jamb Switch - Driver Door Jamb Switch - Passenger Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11670 Door Jamb Switch - Left Rear (Crew Cab) Door Jamb Switch - Right Rear (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11671 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11672 Door Switch: Service and Repair Door Jamb Switch Replacement Removal Procedure 1. Open the door. 2. Remove the screw retaining the door jamb switch (1) to the body. 3. Remove the door jamb switch (1) from the body. 4. Disconnect the electrical connector from the switch. Installation Procedure 1. Connect the electrical connector to the door jamb switch (1). 2. Install the door jamb switch (1) to the body. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11673 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the screw retaining the door jam switch to the body. Tighten the door jamb switch screw to 1.5 Nm (13 lb in). 4. Close the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Harness Routing Views Hazard Warning Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Harness Routing Views > Page 11678 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Harness Routing Views > Page 11679 Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11680 Hazard Warning Switch: Diagrams Component Connector End Views Hazard Warning Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11681 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Disconnect the hazard switch electrical connector. Important: Ensure the tabs retaining the switch to the trim plate are released from the back side of the trim panel. 3. Release the tabs retaining the switch to the trim plate. 4. Remove the switch (1) from the trim plate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11682 Installation Procedure 1. Position the switch (1) to the trim plate. 2. Ensure the switch key-way is indexed to the trim plate. 3. Install the switch to the trim plate ensuring the tabs are fully seated. 4. Connect the hazard switch electrical connector. 5. Install the I/P accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views Headlamp Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11687 Headlamp Switch: Locations Harness Routing Views Harness Routing Views I/P Harness Routing 1 - Accessory Switch X2 2 - Hazard Switch 3 - Accessory Switch X1 4 - Digital Radio Receiver (U2K) 5 - Inflatable Restraint I/P Module 6 - Ambient Light Sensor 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - Courtesy Lamp - Footwell Right 9 - Body Control Module (BCM) X2 10 - X201 (I/P Harness to Body Harness) 11 - HVAC Control Module X1 12 - Auxiliary Power Outlet 2 13 - Auxiliary Power Outlet 1 14 - HVAC Control Module X2 15 - Courtesy Lamp - Footwell Left 16 - Data Link Connector (DLC) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 11688 17 - X204 (Steering Column Harness to I/P Harness) 18 - X208 (I/P Harness to Body Harness) 19 X200 (I/P Harness to Body Harness) 20 - Headlamp and Panel Dimmer Switch 21 - Instrument Panel Cluster (IPC) 22 - Radio X1 23 - Radio X2 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11689 Headlamp Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11690 Headlamp Switch: Service and Repair Headlamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). 2. Remove the screw retaining the switch to the instrument panel (I/P). 3. Partially remove the switch from the I/P. 4. Disconnect the switch electrical connector. 5. Remove the switch from the vehicle. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11691 1. Position the switch to the I/P. 2. Connect the electrical connector to the switch. 3. Install the switch to the I/P. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screw retaining the switch to the I/P. Tighten the screw to 2.5 Nm (22 lb in). 5. Install the knee bolster trim panel. Refer to Driver Knee Bolster Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component Connector End Views Horn Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 11695 Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Removal Procedure Warning: Refer to Servicing the SIR System Warning (See: Restraint Systems/Service Precautions/Servicing the SIR System Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the Inflatable Restraint Steering Wheel module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 3. Remove the horn plunger from the steering column by pressing inward to the stop and by rotating the plunger 90 degrees. 4. Disconnect the screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Connect the screws (1, 4) that secure the contact plate to the steering wheel (3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 11696 Tighten the screws to 5.5 Nm (49 lb in). 3. Install the horn plunger to the steering column. 4. Install the inflator module. Refer to Steering Wheel Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement Multifunction Turn Signal Switch Housing Replacement Removal Procedure 1. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement). 2. Remove the multifunction turn signal switch housing bolts. 3. Remove the multifunction turn signal switch housing. Installation Procedure 1. Install the multifunction turn signal switch housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the multifunction turn signal switch housing bolts. Tighten the bolts to 2.5 Nm (22 lb in). 3. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11702 Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Removal Procedure Note: The turn signal multifunction switch and Inflatable restraint steering wheel module coil are serviced as an assembly. 1. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect any electrical connectors and remove the wiring harness from any retainers as needed. 4. Remove the turn signal multifunction switch bolts. 5. Slide the multifunction turn signal switch off of the steering column. Installation Procedure Note: A new multifunction turn signal switch will come precentered with a centering tab attached. Do NOT remove the centering tab until installation is complete. Failure to follow procedure will cause a misalignment of the multifunction turn signal switch and centering will be required. If reusing the existing multifunction turn signal switch, you must center it. Refer to Inflatable Restraint Steering Wheel Module Coil Centering ( See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures). 1. Slide the multifunction turn signal switch onto the steering column. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11703 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the multifunction turn signal switch bolts. Tighten the bolts to 7 Nm (62 lb in). 3. Route the wire harness assembly down the steering column. 4. Connect any electrical connectors and install the wiring harness through any retainers as needed. 5. Remove the centering tab from the multifunction turn signal switch. 6. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 7. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair Tail Lamp Bulb Replacement Removal Procedure 1. Open the tailgate. 2. Remove the screws (1) from the tail lamp assembly. 3. Remove the lamp assembly. 4. Remove the tail lamp sockets by depressing the locking tab and rotating counterclockwise. 5. Remove the bulbs from the tail lamp and/or side marker lamp sockets. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Page 11708 1. Install the bulbs to the tail lamp, and/or side marker lamp sockets. 2. Install the tail lamp sockets to the tail lamp, rotating clockwise until the locking tab is fully seated. 3. Press the tail lamp to the rear body panel until fully seated. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the tail lamp screws (1) to the tail lamp. Tighten the tail lamp screws (1) to 3 Nm (26 lb in). 5. Close the tailgate. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Service and Repair Trailer Lighting Module: Service and Repair Trailer Lamp Control Module Replacement Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair Park/Turn Signal/Side Marker Lamp Bulb Replacement Removal Procedure Warning Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: * Turn off the lamp switch and allow the bulb to cool before changing the bulb. * Leave the lamp switch OFF until the bulb change is complete. * Always wear eye protection when changing a halogen bulb. * Handle the bulb only by its base. Avoid touching the glass. * Keep dirt and moisture off the bulb. * Properly dispose of the used bulb. * Keep halogen bulbs out of the reach of children. Caution: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Ensure that the headlamp switch is in the OFF position. 2. Ensure that the ignition switch is in the LOCK position. 3. Open the hood. 4. Release the locking tab (1) on the park, turn, daytime running lamp assembly by using a flat-bladed tool and pushing the tab on the lamp outward toward the fender. 5. Rotate the outward edge of the lamp assembly forward. 6. Release the park/turn signal lamp socket (2) by rotating the socket a quarter turn counter-clockwise. 7. Remove the park, turn signal lamp bulb (3). 8. Repeat steps 6 and 7 for the daytime running lamp socket (4) and bulb (5). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 11720 1. Secure the bulbs (3,5) into the bulb sockets (2,4) and to the lamp assembly. 2. Insert the inside edge of the lamp tabs to the grille support. 3. Rotate the lamp assembly into the fender bracket. 4. Push on the outboard edge of the lamp until an audible click is heard, when the lamp assembly is secure to the fender. 5. Inspect the lamps for proper operation. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Turn Signal/Multifunction Switch 2 - Instrument Panel Cluster (IPC) 3 - Hazard Warning Switch 4 - Multifunction Switch - I/P 5 - Ambient Light Sensor 6 - Inflatable Restraint I/P Module 7 - Radio 8 - Accessory Power Outlet - I/P 2 (KC5) 9 - Accessory Power Outlet - I/P 1 10 - HVAC Control Module 11 - Inflatable Restraint Steering Wheel Module 12 - Headlamp Dimmer Switch Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement Multifunction Turn Signal Switch Housing Replacement Removal Procedure 1. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement). 2. Remove the multifunction turn signal switch housing bolts. 3. Remove the multifunction turn signal switch housing. Installation Procedure 1. Install the multifunction turn signal switch housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the multifunction turn signal switch housing bolts. Tighten the bolts to 2.5 Nm (22 lb in). 3. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11726 Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Removal Procedure Note: The turn signal multifunction switch and Inflatable restraint steering wheel module coil are serviced as an assembly. 1. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 2. Remove the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 3. Disconnect any electrical connectors and remove the wiring harness from any retainers as needed. 4. Remove the turn signal multifunction switch bolts. 5. Slide the multifunction turn signal switch off of the steering column. Installation Procedure Note: A new multifunction turn signal switch will come precentered with a centering tab attached. Do NOT remove the centering tab until installation is complete. Failure to follow procedure will cause a misalignment of the multifunction turn signal switch and centering will be required. If reusing the existing multifunction turn signal switch, you must center it. Refer to Inflatable Restraint Steering Wheel Module Coil Centering ( See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures). 1. Slide the multifunction turn signal switch onto the steering column. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 11727 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the multifunction turn signal switch bolts. Tighten the bolts to 7 Nm (62 lb in). 3. Route the wire harness assembly down the steering column. 4. Connect any electrical connectors and install the wiring harness through any retainers as needed. 5. Remove the centering tab from the multifunction turn signal switch. 6. Install the steering column trim covers. Refer to Steering Column Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Cover Replacement). 7. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11737 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11738 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11739 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11745 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11746 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11747 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views Power Window Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11753 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Right Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11754 1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door Harness) Left Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11755 1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11756 Power Window Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11757 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Left Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11758 1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear (A31) 5 - Door Lock Actuator - Left Rear (AU3) Right Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11759 1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 11760 Power Window Switch: Diagrams Component Connector End Views Door Lock/Window Switch - Driver X1 (A31/AU3) Door Lock/Window Switch - Driver X2 (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 11761 Door Lock/Window Switch - Passenger (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 11762 Window Switch - Left Rear (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 11763 Window Switch - Right Rear (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 11764 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel opening. 4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate. 7. If replacing only the switch plate, retain the switches for transfer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11767 Installation Procedure 1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the switches (2, 5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11768 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11769 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the switch plate up and out of the door trim panel. 3. Disconnect the electrical connectors from the switch module. 4. Remove the switch plate assembly from the vehicle. 5. If replacing only the switch module, remove the module from the switch plate. 6. If replacing only the switch plate, retain the switch module for transfer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11770 1. Install the switch module to the switch plate. 2. Connect the electrical connector to the switch module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Removal Procedure Warning Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 1. Remove the front door window regulator. Refer to Front Side Door Window Regulator Replacement (See: Window Regulator/Front Door Window Regulator/Service and Repair/Front Side Door Window Regulator Replacement). 2. Drill a hole (1) through the window regulator bracket and lift arm. 3. Install a nut and bolt through the hole (1) to secure the lift arm while the motor is removed. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 11776 4. Remove the bolts retaining the front window regulator motor to the regulator bracket. 5. Remove the front window regulator motor from the regulator. Installation Procedure 1. Install the front window regulator motor to the regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts retaining the front window regulator motor to the regulator bracket. Tighten the front window regulator motor bolts to 4.5 Nm (40 lb in). 3. Remove the nut and bolt securing the lift arm to the regulator bracket. 4. Install the front window regulator to the front door. Refer to Rear Side Door Window Regulator Replacement (See: Window Regulator/Rear Door Window Regulator/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Removal Procedure 1. Remove the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement (See: Window Regulator/Rear Door Window Regulator/Service and Repair). 2. Remove the bolts retaining the rear window regulator motor to the regulator bracket. 3. Remove the rear window regulator motor from the regulator. Installation Procedure 1. Install the rear window regulator motor to the regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Page 11780 2. Install the bolts retaining the rear window regulator motor to the regulator bracket. Tighten the rear window regulator motor bolts to 4.5 Nm (40 lb in). 3. Install the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement (See: Window Regulator/Rear Door Window Regulator/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views Power Window Switch: Locations Harness Routing Views Harness Routing Views Driver Door Harness Routing 1 - Door Lock and Window Switch - Driver 2 - Speaker - Left Front Door Tweeter (UQ2) 3 - Outside Rearview Mirror - Driver 4 - Outside Rearview Mirror Switch 5 - X202 (Driver Door Harness to Body Harness) 6 - X209 (Body Harness to Driver Door Harness) 7 - Speaker - Left Front Door 8 Window Motor - Driver 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) 10 J500 11 - Door Lock Actuator - Driver Front Passenger Door Harness Routing Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11785 1 - Outside Rearview Mirror - Front Passenger 2 - Speaker - Right Front Door Tweeter (UQ2) 3 Door Lock and Window Switch - Front Passenger 4 - Door Lock Actuator - Front Passenger 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor - Front Passenger 7 - Speaker - Right Front Door 8 - X211 (Front Passenger Door Harness to Body Harness) 9 - X210 (Body Harness to Front Passenger Door Harness) Right Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11786 1 - Door Lock and Window Switch - Right Rear 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear 4 - Window Motor - Right Rear 5 - X317 (Body Harness to Right Rear Door Harness) Left Rear Door Harness Routing (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11787 1 - Speaker - Left Rear Door 2 - Door lock and Window Switch - Left Rear 3 - X316 (Body Harness to Left Rear Door Harness) 4 - Window Motor - Left Rear 5 - Door Lock Actuator - Left Rear Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11788 Power Window Switch: Locations Door Component Views Door Component Views Driver Door Components 1 - Door Lock Actuator - Driver (AU3) 2 - Door Lock/Window Switch - Driver (A31/AU3) 3 - Speaker - Left Front Tweeter (UQ2) 4 - Outside Rearview Mirror - Driver 5 - Outside Rearview Mirror Switch (DE6) 6 - X202 (AU3) 7 - X209 8 - Speaker - Left Front 9 - Window Motor - Driver (A31) 10 Inflatable Restraint Side Impact Sensor (SIS) - Left Connector (ASF) Front Passenger Door Components Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11789 1 - Outside Rearview Mirror - Passenger (DE6) 2 - Speaker - Right Front Tweeter (UQ2) 3 - Door Lock/Window Switch - Passenger (A31/AU3) 4 - Door Lock Actuator - Passenger (AU3) 5 Inflatable Restraint Side Impact Sensor (SIS) - Right Connector (ASF) 6 - Window Motor Passenger (A31) 7 - Speaker - Right Front 8 - X211 (AU3) 9 - X210 Left Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11790 1 - Speaker - Left Rear 2 - Window Switch - Left Rear (A31) 3 - X316 4 - Window Motor - Left Rear (A31) 5 - Door Lock Actuator - Left Rear (AU3) Right Rear Door Components (Crew Cab) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Harness Routing Views > Page 11791 1 - Window Switch - Right Rear (A31) 2 - Speaker - Right Rear Door 3 - Door Lock Actuator - Right Rear (AU3) 4 - Window Motor - Right Rear (A31) 5 - X317 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 11792 Power Window Switch: Diagrams Component Connector End Views Door Lock/Window Switch - Driver X1 (A31/AU3) Door Lock/Window Switch - Driver X2 (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 11793 Door Lock/Window Switch - Passenger (A31/AU3) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 11794 Window Switch - Left Rear (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 11795 Window Switch - Right Rear (Crew Cab with A31) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 11796 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the front of the switch plate up to disengage clip. 3. Remove the switch plate out of the door trim panel opening. 4. Disconnect the electrical connectors (3, 4) from the switches (2, 5). 5. Remove the switch plate assembly (1) from the vehicle. 6. If replacing only the switches, remove the switches from the plate. 7. If replacing only the switch plate, retain the switches for transfer. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11799 Installation Procedure 1. Install the switches (2, 5) to the switch plate (1). 2. Connect the electrical connectors (3, 4) to the switches (2, 5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11800 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11801 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Removal Procedure 1. Remove the 2 screws securing the switch plate assembly to the door trim panel. 2. Lift the switch plate up and out of the door trim panel. 3. Disconnect the electrical connectors from the switch module. 4. Remove the switch plate assembly from the vehicle. 5. If replacing only the switch module, remove the module from the switch plate. 6. If replacing only the switch plate, retain the switch module for transfer. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement - Left Side > Page 11802 1. Install the switch module to the switch plate. 2. Connect the electrical connector to the switch module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear switch plate assembly to the door trim panel with the 2 screws and tighten to 2 Nm (18 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11812 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11813 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11814 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11820 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11821 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11822 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Glass: Customer Interest Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11844 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11845 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 11855 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Glass: All Technical Service Bulletins Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11860 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11861 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 11871 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11872 Front Door Window Glass: By Symptom Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11873 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11874 Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11875 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11876 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11877 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11878 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11879 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 11880 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 11881 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Removal Procedure 1. Position the front door window approximately halfway down. 2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 4. Remove the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (See: Service and Repair/Front Side Door Window Belt Outer Sealing Strip Replacement). 5. Remove the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 11882 6. Lift the window off of the window regulator. 7. Rotate the rear of the window upwards, disengaging the window from the window run channel. 8. Remove the window from between the inner and outer door panels. Installation Procedure 1. Install the front door window into the front door between the inner and outer door panels. 2. Rotate the rear of the window down, positioning the window into the window run channels. 3. Lower the window down onto the window regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the bolts retaining the front door window to the window regulator. Tighten the front window bolts to 9 Nm (80 lb in). 5. Install the front door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement (See: Service and Repair/Front Side Door Window Belt Outer Sealing Strip Replacement). 6. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 11883 7. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement Removal Procedure 1. Position the rear door window in the full up position. 2. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 3. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair). 4. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 5. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 6. Remove the rear window run channel. Refer to Rear Side Door Window Channel Replacement (See: Service and Repair/Rear Side Door Window Channel Replacement). 7. Lower the rear door window in the full down position. 8. Remove the bolts retaining the rear door window to the window regulator. 9. Lift the rear window off the regulator. Carefully lower the window down into the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 11891 10. Remove the window from the door by sliding the window out between the inner panel (1) and the upper window channel (2). Installation Procedure 1. Install the rear door window to the rear door by inserting the front edge of the window into the window channel (3), and sliding the rear of the window down between the upper window channel (2) and the inner panel (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 11892 2. Position the rear door window onto the window regulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts retaining the rear door window to the window regulator. Tighten the rear window bolts to 9 Nm (80 lb in). 4. Raise the window to the full up position. 5. Install the rear door window run channel. Refer to Rear Side Door Window Channel Replacement (See: Service and Repair/Rear Side Door Window Channel Replacement). 6. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 7. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 8. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair). 9. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Regulator: Customer Interest Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11902 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11903 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11909 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 09-08-64-013A > May > 09 > Body - Front Door Glass Inoperative/Binding/Rattling > Page 11910 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11911 Front Door Window Regulator: By Symptom Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11912 Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11913 Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11914 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11915 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11916 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11917 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-013A Date: 090511 Body - Front Door Glass Inoperative/Binding/Rattling TECHNICAL Bulletin No.: 09-08-64-013A Date: May 11, 2009 Subject: Front Door Glass Inoperative, Binding, Rattling Noise (Apply Threadlocker, Tighten Window Regulator Fasteners to Specification) Models: 2007-2009 Chevrolet Colorado 2007-2009 GMC Canyon .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the labor time information. Please discard Corporate Bulletin Number 09-08-64-013 (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the driver or passenger side door glass is inoperative, has a binding condition or a rattling noise. Cause This condition may be caused by the side door glass window regulator mounting bolts loosening. Correction Important Do not replace the door window regulator. Use the following procedure to correct the condition. 1. Remove the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11918 3. Partially lower the side door glass on the affected door to relieve tension on the door glass regulator and to expose the bolts retaining the front door window to the window regulator. Important Do not remove all of the window regulator bolts at the same time because the regulator may fall into the door cavity, causing damage to the inner door components. 4. Locate the front window regulator mounting bolts and studs as shown above (1). Remove the bolts and nuts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the nut or bolt, but do not fully tighten the nut or bolt. Repeat the procedure to the remaining nuts and bolts one at a time. 5. Locate the bolts retaining the front door window to the window regulator. Remove the bolts one at a time and apply GM Medium Strength Threadlocker, Part # 12345382 (in Canada 10953489), to the bolt threads as instructed in the product information. Reinstall the bolts. 6. Tighten the front window regulator fasteners to 12 +/- 2 Nm (106 +/- 17♦lb♦in). 7. Reinstall the front side door water deflector. Refer to Front Side Door Water Deflector Replacement in SI. 8. Reinstall the front side door trim panel on the affected side. Refer to Front Side Door Trim Panel Replacement in SI. 9. Cycle the affected door glass and verify that the condition has been corrected. Parts Information Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 11919 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Handle Replacement Door Window Regulator Handle Replacement Tools Required J 9886-01 Door Handle Clip Remover Removal Procedure 1. Raise the window to the full up position. 2. Remove the window regulator handle from the door by inserting tool J 9886-01 between the handle and the white plastic washer. 3. Align the J 9886-01 with the handle. 4. Push the J 9886-01 in order to disengage the clip. 5. Pull the handle from the door. 6. Remove the window regulator handle from the door. 7. Remove the bearing plate from the door. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11922 Installation Procedure 1. Ensure that the window is in the full up position. 2. Install the white plastic washer to the regulator shaft. 3. Install the retaining clip to the handle. 4. Install the window regulator handle to the door with the handle forward at about a 50 degree angle. 5. Push on the handle until the clip engages on the shaft. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11923 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement Front Side Door Window Regulator Replacement Power window regulator (A31) shown, manual window regulator (without A31) similar. Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Remove the bolts retaining the front door window to the window regulator. 4. Remove the front door window. Refer to Front Side Door Window Replacement (See: Window Glass/Front Door Window Glass/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11924 5. Disconnect the electrical connector from the window regulator motor, if equipped with A31. 6. Loosen the bolts (1) retaining the window regulator to the inner panel at the keyhole slot locations. 7. Remove the remaining fasteners retaining the window regulator to the inner panel. 8. Remove the window regulator from the door by lifting the regulator up, and out of the keyhole slots, and removing the regulator out through the access hole. Installation Procedure 1. Install the front door window regulator into the front door through the access hole. 2. Position the window regulator to the inner panel by sliding the regulator bolts (1) into the keyhole slots in the inner panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fastener retaining the front door window regulator to the door. Tighten the front window regulator fasteners to 9 Nm (80 lb in). 4. Connect the electrical connector to the window regulator motor, if equipped with A31. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 11925 5. Install the front door window. Refer to Front Side Door Window Replacement (See: Window Glass/Front Door Window Glass/Service and Repair). 6. Install the bolts retaining the window to the window regulator. Tighten the front door window bolts to 9 Nm (80 lb in). 7. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 8. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement Manual window regulator (without A31) shown, power regulator (A31) similar. Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 2. Remove the rear inside door handle. Refer to Rear Side Door Inside Handle Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair). 3. Remove the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 4. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 5. Remove the bolts retaining the rear window to the window regulator. 6. Raise and support the rear door window. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11929 7. Disconnect the electrical connector from the window regulator motor, if equipped with A31. 8. Loosen the bolts retaining the window regulator (1) to the inner door at the keyhole slot (2) locations. 9. Remove the bolts retaining the window regulator to the inner panel. 10. Remove the window regulator (1) by lifting the regulator up, and out of the keyhole slots (2) in the inner panel, and removing the regulator out through the access hole. Installation Procedure 1. Install the rear door window regulator (1) into the rear door through the access hole. 2. Position the rear door window regulator to the inner panel by inserting the regulator bolts to the keyhole slots (2) on the inner panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts retaining the rear door window regulator to the inner panel. Tighten the rear window regulator bolts to 9 Nm (80 lb in). 4. Connect the electrical connector to the window regulator motor, if equipped with A31. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11930 5. Remove the window support and lower the window onto the window regulator carrier plate. 6. Install the bolts retaining the window to the window regulator. Tighten the rear window bolts to 9 Nm (80 lb in). 7. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). 8. Install the rear door speaker. Refer to Radio Rear Side Door Speaker Replacement (See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Radio Rear Side Door Speaker Replacement). 9. Install the rear door inside handle. Refer to Rear Side Door Inside Handle Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Handle/Rear Door Interior Handle/Service and Repair). 10. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: Customer Interest Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 11939 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: Customer Interest Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11949 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: All Technical Service Bulletins Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 11958 Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: All Technical Service Bulletins Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11968 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures Windshield: Procedures Windshield Glass Cleaning Clean the windshield with windshield cleaner, GM P/N 1050011 (Canadian P/N 992727) or equivalent. The cleaner should not harm the paint finish or scratch the glass. The glass is clean when the water no longer beads, but sheets across the entire glass surface. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11975 Windshield: Removal and Replacement Windshield Replacement Windshield Replacement Special Tools * J 24402-A Glass Sealant Remover (Cold Knife) * J 39032 Stationary Glass Removal Tool * Use a urethane adhesive systems which meet GM Specification GM 3651G Removal Procedure Note: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Remove the fixed antenna mast. Refer to Fixed Antenna Mast Replacement (See: Accessories and Optional Equipment/Antenna/Antenna Mast/Service and Repair). 2. Open the hood. 3. Remove the window wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair ). 4. Remove the cowl air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair). 5. Remove the inside rear view mirror. Refer to Inside Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Inside Rearview Mirror Replacement). 6. Pull back and position the auxiliary weatherstrip away from the pinch-weld flange. Note: Both doors need to be opened. 7. Remove the windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement (See: Windshield Side Reveal Molding Replacement). Warning: Refer to Glass and Sheet Metal Handling Warning (See: Body and Frame/Service Precautions/Glass and Sheet Metal Handling Warning). Warning If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 8. Cover to protect the following parts from broken glass: * Upper dash pad * Defroster outlets and A/C outlets * Seats and carpeting Note: The window lower supports (1) have molded in locks with an urethane adhesive strip (2) on the back side. Once the window lower stop have been removed they must be replaced. 9. Remove the window lower supports (1) by using a flat-bladed tool, lightly prying upward in the middle until it releases. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11976 Note: Keep the cutting edge of the tool against the window. 10. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinch-weld flange. * The only suitable lubrication is clear water. * Use J 24402-A , J 39032 or equivalent in order to remove the window. 11. Remove the bottom of the window from the urethane adhesive using a long utility knife or similar tool. Keep the cutting edge of the utility knife against the glass. 12. With the aid of an assistant (2) remove the window (1) from the vehicle. Installation Procedure 1. Install a stationary window into the opening. Refer to Adhesive Installation of Stationary Windows (See: Windows/Service and Repair/Adhesive Installation of Stationary Windows). 2. Install the window side reveal moldings to the vehicle. Refer to Windshield Side Reveal Molding Replacement (See: Windshield Side Reveal Molding Replacement). 3. Reposition the auxiliary weatherstrip to the pinch-weld flange. 4. Install the antenna mast. Refer to Fixed Antenna Mast Replacement (See: Accessories and Optional Equipment/Antenna/Antenna Mast/Service and Repair). 5. Install the cowl air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair). 6. Install the window wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 7. Install the inside rear view mirror. Refer to Inside Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Inside Rearview Mirror Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11977 8. Close the hood. 9. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Windshield Side Reveal Molding Replacement Windshield Side Reveal Molding Replacement Removal Procedure 1. Open the doors 2. Partially remove the auxiliary weatherstrip (2). 3. Gently pry the reveal molding (1) from the top working towards the air inlet panel. 4. Release the reveal molding from the pinchweld flange. 5. Remove the reveal molding from the windshield pillar. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11978 1. Install the reveal molding under the air inlet panel grille. 2. Align the reveal molding to the pinchweld flange and to the top roof header. 3. Press the reveal molding (1) onto the pinchweld flange. 4. Reposition the auxiliary weatherstrip (2). 5. Close the doors. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair Windshield Washer Hose Replacement Removal Procedure 1. Raise and support the hood. 2. Remove the washer hose from the nozzles. Refer to Washer Nozzle Replacement (See: Windshield Washer Spray Nozzle/Service and Repair). 3. Remove the hose from the air inlet panel. 4. Disconnect the hose (1) from the washer pump. 5. Install a cap on the washer pump outlet in order to prevent excessive washer solvent loss. 6. Remove the washer hose from the vehicle. Installation Procedure 1. Position the new hose to the vehicle. 2. Remove the cap from the washer pump outlet and install the new hose to the outlet of the pump. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 11987 3. Position the hose (1) to the air inlet panel (4). 4. Secure the hose to the air inlet grille panel. 5. Connect the hose to the washer nozzles. Refer to Washer Nozzle Replacement (See: Windshield Washer Spray Nozzle/Service and Repair). 6. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair). 7. Top off the washer solvent container with washer solvent. 8. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Pump: Diagrams Component Connector End Views Windshield Washer Fluid Pump Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 11991 Windshield Washer Pump: Service and Repair Washer Pump Replacement (2nd Design) Removal Procedure 1. Raise and support the hood. 2. Remove the washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Windshield Washer Reservoir/Service and Repair). 3. Pull the top of the pump outward in order to release the pump from the container. 4. Using 2 flat-bladed tools under the pump, gently pry in opposite directions in order to release the pump from the grommet. 5. Remove the washer pump (1) from the washer container. 6. Discard the washer pump grommet. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 11992 1. Install the new washer pump (1) and grommet into the washer solvent container. 2. Use clean washer solvent on the washer pump in order to aid in the installation of the new washer pump into the grommet. 3. Apply downward pressure onto the pump in order to seat the pump to the grommet. 4. Secure the top of the pump to the washer container. 5. Install the washer solvent container. Refer to Windshield Washer Solvent Container Replacement (See: Windshield Washer Reservoir/Service and Repair). 6. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) for the 2.8L (LK5) engine or Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) for the 3.5L (L52) engine. 2. Remove the washer container to fender flange fasteners (1,2). 3. Remove the coolant reservoir to wheelhouse fastener (3). 4. Slightly raise the container to access the electrical connection. 5. Disconnect the electrical connector from the washer pump. 6. Remove the washer hose from the washer pump spout. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 11996 7. Disengage the coolant recovery hose clips from the fender flange. 8. Remove the washer solvent container / coolant recovery reservoir (1) from the engine compartment. 9. Drain the washer solvent and engine coolant into separate suitable containers. 10. Place the washer solvent container / coolant recovery reservoir onto a clean bench top. 11. Remove the following component parts: * Coolant container overflow hose (1) * Coolant recovery reservoir cap (2) * Windshield washer container cap (3) * Coolant recovery to radiator hose (4) * Windshield washer pump and grommet (5) * Windshield washer container lower grommet (6) 12. Discard the washer solvent container / coolant recovery reservoir (7). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 11997 Installation Procedure 1. Position a new washer solvent container / coolant recovery reservoir (7) on the bench top. 2. Install the following component parts: * Coolant container overflow hose (1) * Coolant recovery reservoir cap (2) * Windshield washer container cap (3) * Coolant recovery to radiator hose (4) * Windshield washer pump and a new grommet (5) * Use clean washer solvent on the washer pump grommet to aid in the pump installation. * Windshield washer container lower grommet (6) 3. Position the washer solvent container / coolant recovery reservoir (1) to the engine compartment and fender flange. 4. Secure the washer hose to the washer pump spout. 5. Connect the electrical connection to the washer pump. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 11998 6. Route and engage the coolant recovery hose clips to the fender flange. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the washer container to fender flange fasteners (1,2). 9 Nm (80 lb in) 8. Install the coolant recovery reservoir to wheelhouse fastener (3). 9 Nm (80 lb in) 9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) for the 2.8L (LK5) engine or Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) for the 3.5L (L52) engine. 10. Fill the washer solvent container with clean washer solvent. 11. Fill the coolant recovery reservoir with new engine coolant per manufacturer's specification. 12. Test the washer system and inspect for leaks. 13. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair Windshield Washer Spray Nozzle: Service and Repair Washer Nozzle Replacement Removal Procedure 1. Raise and support the hood. 2. Remove both wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service and Repair). 3. Remove the fixed antenna mast. Refer to Fixed Antenna Mast Replacement (See: Accessories and Optional Equipment/Antenna/Antenna Mast/Service and Repair). 4. Remove the retainers (1, 3, 5) securing the air inlet panel grille (2) to the cowl panel. 5. Remove the air inlet panel from around the hood hinges. 6. Roll the air inlet panel (4) forward. 7. Disconnect the hose from the washer nozzles (2, 3). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Page 12002 8. Press the tabs on the washer nozzles and remove the nozzles from the air inlet panel. 9. Remove the washer nozzle from the air inlet panel. Installation Procedure 1. Position the nozzles to the air inlet panel. 2. Press the nozzles into the panel in order to secure. 3. Install the hose to the nozzles (2, 3). 4. Secure the hose to the air inlet panel. 5. Ensure the foam washers (2) are secure to the retainers (1) prior to installing the air inlet grille panel (3) to the cowl. 6. Position the air inlet panel around the hood hinges. 7. Secure the retainers (1) to the cowl panel. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Page 12003 8. Install the retainers (5) to the air inlet panel (2) in order to secure. 9. Install the fixed antenna mast. Refer to Fixed Antenna Mast Replacement (See: Accessories and Optional Equipment/Antenna/Antenna Mast/Service and Repair). 10. Install the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service and Repair). 11. Close the hood. 12. Test the washer spray pattern. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair Windshield Wiper Arm Replacement Special Tools J 39637 Wiper Arm Puller Removal Procedure 1. Open the hood. 2. Remove the wiper arm nut cap(s) and discard. 3. Remove the wiper arm nut (2) from the wiper arm (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 12007 4. Using a J 39637 or equivalent, remove the wiper arm from the wiper arm pivot shaft if the wiper arm fails to release from the pivot shaft with a rocking motion. 5. Release the wiper arm blade (2) from the wiper arm (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 12008 6. Clean the pivot shaft knurls (1) with a soft wire brush. Installation Procedure 1. Install the wiper arm blade (2) to the new wiper arm (1). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 12009 2. Lift the wiper blade off the windshield and install the wiper arm (1) to the wiper arm pivot shaft (2). 3. Align the tip of the wiper blade with the round dot in the blackout area of the windshield. 4. For the passenger side blade (2), ensure the wiper blade tip is held in position to the alignment dot (1) on the windshield. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 12010 5. For the driver side blade (2), ensure the wiper blade tip is held in position to the alignment dot (1) on the windshield. 6. Holding the wiper blade to the windshield dot, install the wiper arm nut. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Continue holding the wiper blade in position while tightening the nut. Tighten the wiper arm nut to 33-38 Nm (24-28 lb ft). 8. Install new wiper arm nut covers. 9. Close the hood. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 12015 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures Wiper Blade: Procedures Wiper Blade Element Cleaning Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures > Page 12018 Wiper Blade: Removal and Replacement Windshield Wiper Blade Replacement Windshield Wiper Blade Replacement Removal Procedure Important: Do not allow the wiper arm (1) to fall back and strike the windshield. 1. Lift the wiper arm and hold in the upright position. 2. Push upward the locking tab (3) of the wiper blade clip and pull downward on the wiper arm blade (2). 3. Remove the wiper blade from the inside radius of the wiper arm. 4. Bring the wiper arm out through the opening in the wiper blade. Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures > Page 12019 1. Position the wiper blade in the inside radius of the wiper arm hook. 2. Insert the hook of the wiper arm through the opening in the wiper blade (2). 3. Pull upward until the locking tab (3) of the pivot engages the slot in the hook. 4. Carefully lower the wiper arm and blade onto the windshield. Wiper Blade Element Replacement Wiper Blade Element Replacement Removal Procedure Important: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. Refer to Windshield Wiper Blade Replacement (See: Windshield Wiper Blade Replacement). 2. Disengage the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). Installation Procedure Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures > Page 12020 Important: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Refer to Windshield Wiper Blade Replacement (See: Windshield Wiper Blade Replacement). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair Windshield Wiper Transmission Replacement Special Tools * J 39232 Wiper Linkage Separator * J 39529 Wiper Linkage Installer Removal Procedure 1. Place the wiper arms in the 1/2 wipe position. 2. Turn the ignition key to the OFF position. 3. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service and Repair). 4. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair). 5. Disconnect the electrical connector (3) for the wiper motor. 6. Push the electrical harness grommet (1) through the plenum panel into the cowl. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 12024 7. Remove the transmission fasteners (1, 4). Twist the transmission assembly in order to remove the transmission assembly from the cowl. 8. Remove the transmission (3) from the vehicle through the access openings in the top of the cowl. Installation Procedure 1. Install the transmission (3) to the cowl area of the plenum. A slight twisting motion is needed in order to install. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission mounting bolts (1, 4). Tighten the wiper transmission mounting bolts to 9 Nm (81 lb in). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 12025 3. Position the electrical harness grommet to the plenum panel hole (5). 4. Pull the harness toward the front of the vehicle in order to seat the harness grommet. 5. Connect the electrical connector. 6. Install the connector position assurance tab (CPA) to the harness connector. 7. Cycle the wiper system 1 time with the wiper motor switch. 8. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair). 9. Install the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service and Repair). 10. Test the wiper system. Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Harness Routing Views Wiper Motor: Locations Harness Routing Views Harness Routing Views Body Harness Routing 1 of 3 (Regular Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness), X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Harness Routing Views > Page 12030 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Extended Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Powertrain Control Module (PCM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Harness Routing Views > Page 12031 19 - A/C Refrigerant Pressure Sensor (C60) Body Harness Routing 1 of 3 (Crew Cab) 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - G105 7 - X102 (Body Harness to Chassis Harness) 8 - X105 (4WD)/X106 (2WD) (Engine Harness to Body Harness) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 - Fuse Block Underhood X7 12 - Fuse Block - Underhood X6 13 - X104 (Forward Lamp Harness to Body Harness) and X103 (Forward Lamp Harness to Body Harness) 14 - G106 15 - Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor (C60) Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Harness Routing Views > Page 12032 Wiper Motor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left and Right Sides of Engine Compartment Components 1 - Wheel Speed Sensor (WSS) - Left Front 2 - Brake Fluid Level Switch 3 - Windshield Wiper Motor 4 - Pass-through Grommet 5 - Electronic Brake Control Module (EBCM) 6 - JX105 7 - X102 8 - X105 (4WD)/X106 (2WD) 9 - Fuse Block - Underhood X4 10 - Fuse Block - Underhood X5 11 Fuse Block - Underhood X7 12 - Fuse Block - Underhood X6 13 - X103 and X104 14 - JX106 15 Wheel Speed Sensor (WSS) - Right Front 16 - Engine Control Module (ECM) X1 Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Harness Routing Views > Page 12033 17 - Windshield Washer Fluid Pump 18 - Pass-through Grommet 19 - A/C Refrigerant Pressure Sensor Rear of the Engine Compartment Components - 2 of 2 1 - Windshield Washer Fluid Pump 2 - Windshield Wiper Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 12034 Wiper Motor: Diagrams Component Connector End Views Windshield Wiper Motor Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 12035 Wiper Motor: Service and Repair Windshield Wiper Motor Replacement Special Tools * J 39232 Wiper Linkage Separator * J 39529 Wiper Linkage Installer Removal Procedure 1. Place the wiper arms in the 1/2 wipe position. 2. Turn the ignition key to the OFF position. 3. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service and Repair). 4. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair). 5. Remove the wiper transmission (3). Refer to Windshield Wiper Transmission Replacement (See: Wiper Gear Box/Service and Repair). 6. Using the J 39232 , separate the transmission link from the wiper motor crank arm ball stud. 7. Remove the fasteners from the wiper motor to the frame assembly. 8. Remove the wiper motor. Installation Procedure 1. Install the wiper motor onto the wiper transmission frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 12036 2. Install the bolts in order to secure the motor to the frame. Tighten the wiper motor mounting bolts to 9 Nm (81 lb in). Note: Lubricate the socket with Multi-Purpose Lubricant, Superlube, GM P/N 12346241 (Canadian P/N 10953474) or equivalent. 3. Install the transmission drive link socket onto the crank arm ball of the wiper motor using the J 39529 . 4. Install the wiper transmission (3) to the plenum. Refer to Windshield Wiper Transmission Replacement (See: Wiper Gear Box/Service and Repair). Chevrolet Colorado 2wd Workshop Manual (V8-5.3L (2009)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label